Replacing a fuel pump can be seen as a complicated job for a number of reasons; firstly, the most critical element of the job is the component itself – a faulty pump can spell disaster for your entire fuel system – and secondly, it is often labour-intensive and precise, so that the pump is installed properly. Fuel pumps are tricky to access, especially in modern vehicles, as they are usually mounted inside the fuel tank. Fuel pumps themselves are relatively inexpensive, but replacing one can cost you anywhere from $400 to $1,200 depending on your car’s make and model, due in no small part to a labor cost that can run anywhere between one and four hours on average. In luxury or performance vehicles, fuel pump replacement can run 25-30% higher due to special parts and more advanced engineering.
When an engine runs, the fuel pump is one of the components that are working the hardest to make sure fuel gets into the combustion chamber at the correct pressure; which is typically 35-65 psi for most vehicles. If this pressure is not maintained, misfires, stalling and lack of acceleration will occur. With a growing number of valves, electronic components, and other systems linked to the fuel pump in both surprises and complexity, vehicle replacement has become more complicated. For example, many modern fuel pumps are not only physically removed from the tank, but also electrically wired to electronic control systems, sensors, and fuel filters, all of which have to be disconnected and then reconnected during the replacement process. The latest report from the Automotive Aftermarket Suppliers Association (AASA) underscores the growing complexity of vehicle fuel systems as cars age, meaning that mechanics should be more careful than ever when replacing the fuel pump.
In certain vehicle makes, dropping or removing the fuel tank is necessary to access the pump, requiring extra labor and technical expertise. Industry research conducted by RepairPal found that one in four fuel pump replacements requires removing the fuel tank, a labor-intensive and often complicated process. Also, if the fuel tank is not properly handled at the time of removal, it can lead to fuel spillage or even ignition, which it an dangerous task.
This same complexity is also driven by the fact that there are many different types of fuel pump designs utilized in different vehicles. Some pumps can be externally accessed, but others are part of the fuel tank itself. In diesel engines, for example, the pressure at which fuel pumps work is very high and in terms of installation, they need very accurate calibration. And while not purchasing a new fuel pump does not seem significant concern at all after that specific repair can amount to thousands where to even fix the pump can cost more than what you paid for it. About 30 percent of diesel engine problems are associated with the failure of the fuel pump, Diesel Technology Forum (DTF) notes, highlighting how critical proper installation is.
Replacing a fuel pump is then prone to another problem of more damage. That will also help prevent any debris or contaminants from the failing fuel pump entering the fuel lines or injectors during the replacement, which could lead to further problems such as engine damage. Then you often need to clean and inspect the entire fuel system, which can complicate and extend the job. According to a study from the National Institute for Automotive Service Excellence (ASE), issues can result in 40 percent of fuel pump replacements when the fuel lines or injectors aren’t dried out sufficiently or inspected thoroughly.
All in all, replacing a fuel pump is a maintenance item, but it is an involved procedure that requires a great deal of skill, takes a long time to perform, and can lead to any number of erroneous results if performed improperly. When you are struggling with fuel pump issues, you should always look for a trusted provider that can take care of the details of the replacement process. To learn more about fuel pumps and how to replace them, go to Fuel Pump.