How to replace your cars fuel pump in three easy days
My truck, over the last few months, had developed a lovely little penchant for not wanting to restart once warmed up. This wasn't to bad as long as I didn't plan on being anywhere less than 3 hours, and kept my wife from sending me to the store. But with summer here and wanting to be able to run off and go fishing I decided to fix it. After doing some diagnostics I think the most likely culprit was a fuel pump that was sticking as it heated up, and I thought this info might help anyone needing to replace theirs.
Day one, we'll spend this day dropping the fuel tank. Those repair manuals are really helpful, just slide a jack under the tank, unbolt the straps, drop the tank, disconnect the fuel lines and you're done. The reality is just a little different. Firstly the entire time you're working under your car a gently rain of road grime consisting of grease, dirt and decayed road kill will be falling into your eyes, ears and mouth. Second, there's a lot more lines going to the fuel tank than the manuals say, after sweating and swearing over trying to remove the spring clips the best option is just to cut any rubber lines since after 10 years they're all rotten anyways. Now struggle blindly to maneuver the fuel line disconnect tool into position by feel, while pushing the tool into the connection shove the fuel line in the direction of the tool while simultaneously stabilizing the fuel tank with your head. Once all the lines are cut or disconnected lower the tank using a jack, a couple of coffee cans and a bunch of short pieces of 2x4 and drag out from under the vehicle. Unscrew the fuel pump assembly and remove from tank, then detach fuel pump from fuel pump assembly. you are now done for day one since your wife has the other car.
Day two, taking a section of each of the lines you cut, along with your old fuel pump, visit an autoparts store, hand the lines to the clerk and ask him for 3 feet of each size, now marvel in wonder as he LOSES the pieces you gave him between you and the back of the store. Smile nicely as he tries to explain what happened and then say "Umm No I don't need anything else" and leave. Go to second auto parts store where they will try to sell you, first, the wrong pump, and then, when they finally admit it won't work, they try to sell you the entire fuel pump assembly, say "Let me think about it". Go to dealer, laugh hysterically and vociferously ejaculate "Oh Heck, No!" when they say the pump is $439.00 and will be in Monday. Lastly drive to the final remaining autoparts store and say "Please tell me you have a fuel pump like this one" and rejoice when the guy say "Sure, you need the Bosch with the adapter socket, I can have it here by three". Weep with joy, go home and wait until three.
Day three, the true horror is that we now reverse the steps taken on day one and there is no way to test if everything works until the last bolt is tightened, however day three began with a stuffed up head and severe vertigo caused by allergies, apply medication and go back to bed for several hours until you can stand without puking. When well enough, reverse the steps of day one. Fortuitously the majority of the road grime will have fallen on you already and this time it will be as refreshing as a summer's shower. Add two gallons to clean gasoline and start the vehicle, when the vehicle fails to start remember that you disconnected the battery. Remedy that and marvel when your vehicle starts, but the joy will be short lived when you remember that, oh yeah, it would start before. So now, hold out hope that it won't have the hot start problem anymore, but you'll never know if it will happen again, unless it happens again.