To change the fuel pump, the fuel tank have to be lower from the body of the truck. On height of the hefty weight that the tank, fuel is a volatile liquid, making it dangerous come handle. Back difficult, this job can be completed with the appropriate equipment and patience.

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This article uses to the second generation Dodge lamb (1994-2001).

The fuel pump, filter, and also sending unit are all situated in the fuel tank together one assembly. The fuel pump is electric and driven through a long-term magnet electric motor. As the rotor within the pump turns, fuel is attracted into the pump and pressurized throughout the fuel system. The fuel sending unit"s float lever drops v the fuel level in the tank. The sending unit is a change resistor, meaning the sensors resistance to existing flow transforms as its position moves. This change in existing is presented by the driver"s information facility (gas gauge). Fuel pollution from dirt and also water is the main resource of damages to fuel device components. One means to alleviate your chances of drawing in dirt and also water indigenous the main tanks in ~ gas train station is by pour it until it is full up as soon as the station is not being re-supplied. Also, station with more business tend to have actually fresher gas.

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Materials NeededBasic tool collection (ratchet, sockets, screwdrivers, pliers)HammerStrap wrench10mm wrenchFuel tank siphon pumpOne or more floor jacks, stands, and also blocks of lumber (if necessary)Electrical tape (optional)Fuel press gauge with drainpipe hose (optional)

There are several methods to change the fuel pump. The many common method is by dropping the fuel tank, which will be spanned here. The bed that the truck deserve to be tilted or removed. A hole have the right to be cut in the bed directly above the fuel pump together well.

Have her fuel level together low as feasible before removal of the tank. Every gallon the fuel weighs six pounds, so each gallon lighter her tank is, the much less you have to worry around handling.

Step 1 – collection the emergency brake

If you need an ext room under the rear of your truck, place wheel chocks in former of the former wheels and also raise it with a floor jack. Ar jack stand on every side versus the framework rails. Block of wood have the right to be used to reduce damage caused by the sharp areas of the jack stands.

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Figure 1. Place a jack stand versus the framework rail.

Step 2 – Disconnect battery and siphon fuel native tank

Use a 10mm wrench to eliminate the negative (black) battery cable. Location it in one area it can not accidentally call the battery, or wrap that with electrical tape.

Use a suitable siphon pump to eliminate excess fuel from the tank. Tanks filled with fuel have the right to weigh in access of 200 pounds, making that very challenging to remove.

Step 3 – relieve the fuel pressure

Find the fuel pump fuse and also remove it. There must be a diagram on the peak or bottom the the under-hood fuse crate cover with its location. When removed, begin the engine and also wait for the engine to stall ~ above its own.

If the fuel pump is not working, locate the pressure relief valve top top the fuel rail. You will should push the tiny valve in through a driver or connect a fuel press gauge through a drain hose. Be careful using the screwdriver an approach because fuel will certainly spray out in every directions.

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Figure 2. Within the red circle is the fuel press relief valve.

Step 4 – ease the fuel tank straps

Loosen the straps utilizing a 15mm socket, yet do not totally remove them. As soon as they space loosened, remove the skid key on the front and also side of the fuel tank.

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Figure 3. You deserve to see the 2 straps stop this fuel tank to the truck.

Step 5 – Disconnect fuel filler neck from body of truck

When you open up the fuel door, you will certainly see three or four Phillips head screws surrounding the filler hose opening. As soon as these room removed, ease the fuel filler hose and also vent water tap clamps located near the filler neck. Pull the hoses away from the fuel filler neck.

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Figure 4. The red circles show the locations of the Phillips screws and hose clamps.

Step 6 – Disconnect electrical connector and also fuel press hose

Lower the tank down as much as feasible without damaging the hoses attached come the fuel pump. Once enough space is made, reach up, disconnect the electric connector by advertise on the red locking tab, and squeezing the flexible tab top top the connector plug. When squeezing, traction the connector plug away from the fuel pump.

To eliminate the fuel press hose, squeeze the sides of the plastic rapid disconnect fitting and also pull the hose far from the fuel pump.

Before lowering the tank come the ground, twin check there room no various other connections come the tank.

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Figure 5. A view of the peak of the fuel pump with the fuel hose and also electrical connector removed.
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Figure 6. Number one suggests the electric connector, and number two suggests the fuel pressure hose.

Step 7 – replace fuel pump

You will see a plastic lock ring bordering the fuel pump assembly. It have the right to be gotten rid of with a strap wrench type tool, or utilizing a screw driver/punch and a hammer. Usage a screwdriver to pry the fuel pump assembly away from the rubber O-ring and lift the fuel pump the end of the tank.

Before installation the new fuel pump, do sure any type of parts that were not contained with the brand-new assembly are transferred over. The brand-new pump"s indict should administer the specifics. Install the brand-new rubber O-ring onto the tank. Make certain it stays level/in-place together the brand-new pump is gift installed. Position the new pump at an angle to first insert the sending unit"s float, and also then push the fuel pump under onto the O-ring. Tighten the plastic lock ring, and get prepared to download the tank earlier onto the truck.

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Figure 7. The fuel pump assembly.

Step 8 – raise tank right into the truck and reconnect hoses

Raise the tank high enough to begin tightening a fuel tank strap. Save enough an are between the tank and also the truck to connect the electric connector as well as the fuel push hose come the fuel pump. Proceed raising the fuel tank till you have the right to re-connect the fuel filler hose and vent hose. As soon as connected, connect the fuel filler neck come the human body of the truck. On slide the skid plates back into place and also tighten the tank under to the truck through the tank straps.

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Step 9 – inspect for leaks

Re-connect the an adverse battery cable and also install the fuel pump fuse. Turn the ignition on and also inspect roughly the fuel tank because that leaking fuel. If nobody is found, the surroundings is done!

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Figure 8. If you see fuel leaking indigenous the tank, clean the area and also tighten the fuel pump lock ring. If fuel is quiet leaking, the rubber O-ring will should be replaced.

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