Repair 7

Fuel pump failure will stop a car in its tracks. An engine sputtering and shutting off is the most notable sign of pump failure. If there is gas in your tank and your car sputters and shuts down you may need to replace your fuel pump. The fuel pump is located inside your gas tank and it can be replaced within two to five hours with all of the proper tools.

Instructions

Relieve Fuel Pressure

1

Remove the gas cap to relieve any pressure in the gas tank.

2

Disconnect the wiring for the fuel pump assembly that is located behind the fuel filter hose, if you have a model with port fuel injection. The fuel filter hose is near the fuel filter just in front of the back tire on the passengers side.

3

Run the engine until it uses all of the remaining fuel and stops running.

4

Disconnect the negative battery terminal.

Remove Fuel Tank

5

Siphon gas out of your tank or use the fuel up if it is more than one-eighth full. Use a siphon pump to siphon fuel out of your vehicle. Insert one hose end in to the gas tank and the other in to a fuel-safe container. Pump the fuel out of the tank into the container.

6

Engage the emergency brake and block the front wheels. Raise the back of your vehicle up with a jack and place it on jack stands. Remove the jack.

7

Disconnect the wiring for the fuel pump assembly if you have not already done so. Disconnect the vapor return hose, the filler neck, and the vent tubes. Disconnect the fuel feed hose, and the fuel-return hose as well.

8

Support the fuel tank with the jack and remove both restraining straps. Lower the tank until you can access the wires and remove the ground strap and the wire.

9

Lower the fuel tank to the ground and bring it out from under your car.

Remove the Fuel Pump

10

Using a punch and hammer, gently tap the inner ring counter clockwise until the inner cams are free.

11

Pull the fuel pump out of the tank. Make sure not to bump it on anything because the fuel level float and the fuel sending unit are delicate and even a small bump will render the readings inaccurate.

12

Check the o-ring on top of the fuel pump and the filter on the bottom of it. If the o-ring is cracked or dry, replace it. If the filter cannot be cleaned, it must be replaced.

Your 2000 Dodge Intrepid fuel pump is the component that pressurizes the gasoline in the car, which allows the fuel injectors to supply the engine with fuel. Replacing the fuel pump is a relatively simple procedure that can be done at home. However, in order to access the fuel pump, you must remove the fuel tank, which is a separate procedure you should know how to perform.

Instructions

Relieving the Fuel System Pressure

1

Take out the fuel filler cap.

2

Disconnect the fuel pump relay from the power distribution center, located in the engine compartment. The relays should be identified under the cover of the power distribution center.

3

Start your Intrepid engine, and leave it running, until it dies. Crank the engine several times. Remove the key from the ignition.

4

Attach the fuel pump relay back into the power distribution center.

5

Remove the negative battery cable from the remote ground terminal, located on the right fender in the engine compartment, using a wrench to remove the retaining bolt. Pull out the cable.

Removing the Fuel Pump

6

Detach the fuel tank from your Intrepid. This is a separate procedure. The fuel pump module is found on the fuel tank.

7

Remove the fuel lines and electrical connectors from the fuel pump module. This can be done, depending on what fitting was installed in the fuel pump, which includes a singe-tab type, a two-tab type or a plastic ring type. Tabbed fittings need to be squeezed, so they loosen enough to allow for the lines to pull apart. The tab on a single-tab fitting needs to be discarded and replaced. Loosen a plastic ring type fitting, by pushing in the locking ring.

8

Loosen the module locknut, by turning it, counterclockwise, using large channel locks pliers.

9

Lift out the fuel pump module from the tank at an angle. Do not to break off the fuel-level sending float unit when removing the module. Clean any spilled fuel with rags.

10

Place the fuel pump module in a container or drain pan.

11

Replace the seal to where the fuel pump module is placed on the fuel tank. Wipe down the tank-sealing surface with rags.

12

Insert the new fuel pump module. Line up the tabs, under the module, with the notches on the fuel tank.

13

Screw the fuel pump module locknut tight, to about 40 ft-lbs., either by hand or with your channel locks pliers.

14

Attach the electrical connections and the fuel lines to the new fuel pump module.

15

Install the fuel tank back onto your Intrepid.

16

Attach the negative battery cable to the stud, and tighten the bolt with your wrench. Install the fuel filler cap.

The Duramax is a series of eight-cylinder diesel engines manufactured by General Motors and Isuzu since 2001. General Motors uses these engines in larger, heavy-duty trucks. For example, the 6.6-liter Duramax is an engine option in the 2002 Chevrolet Silverado 2500HD pickup truck. The water pump circulates coolant around the engine to prevent it from overheating. The water pump on a 2002 Duramax diesel engine is on the front of the engine and is accessible from the left-front wheelhouse of the vehicle.

Instructions

1

Disconnect the inner panel for the left-front wheelhouse with a socket wrench. Place a drain pan under the radiator drain, and remove the radiator drain plug. Drain the coolant into the drain pan, and replace the drain plug.

2

Disconnect the housing for the thermostat and the clutch for the cooling fan with a socket wrench. Remove the balancer from the crankshaft. Disconnect the mounting nuts for the outlet hose, and detach the hose from the water pump. Disconnect the retainer for the engine wiring harness from the outlet hose of the water pump.

3

Remove the mounting bolt from the water pump with a socket wrench. Record the locations of each bolt, since they have different lengths. Detach the water pump and its gasket from the engine.

4

Lubricate the gasket for the water pump with engine oil, and replace the gasket. Install the new water pump and tighten its mounting bolts to 15 foot-pounds with a torque wrench.

5

Connect the retainer for the engine wiring harness to the outlet hose for the water pump. Attach the outlet hose to the water pump and tighten its mounting nuts to 15 foot-pounds with a torque wrench. Replace the thermostat housing and crankshaft balancer with a socket wrench. Install the clutch for the cooling fan.

6

Fill the radiator with coolant. Replace the inner panel for the wheelhouse in the left-front fender.

The water pump in the 1998 Ford Explorer is located on the front of the engine block by the cooling fan. It circulates coolant through the block to prevent the engine from overheating during its operation. The primary symptom of a faulty water pump is a continually increasing engine temperature, even with the proper amount of coolant. A malfunctioning water pump causes excessive wear to the engine and may eventually damage the engine permanently.

Instructions

1

Disconnect the batterys negative terminal with a socket wrench. Position a drain pan under the radiator and open the radiator drain. Replace the plug after the coolant is completely drained from the radiator.

2

Disconnect the cooling fan shroud with a socket wrench. Remove the mounting bolts for the cooling fan. Remove the cooling fan assembly. Disconnect the accessory drive belt.

3

Detach the water bypass hose and heater hose from the water pump. Disconnect the brackets for the wiring harness of the engine control sensor, and push the wiring harness out of the way. Remove the attaching bolts for the water pump pulley with a socket wrench and disconnect the pulley.

4

Remove the attaching bolts for the water pump. Record the position of each bolt since they have different lengths. Detach the pump from the front engine cover. Disconnect the radiator hose from the water pump. Remove the pump from the vehicle and discard its gasket.

5

Clean the mounting surfaces of the pump and front engine cover with a shop towel. Apply a layer of gasket sealer to both sides of the new gasket. Mount the gasket onto the water pump.

6

Connect the radiator hose to the new pump. Install the pump and place the mounting bolts in the correct holes that you recorded earlier. Torque the mounting bolts to between 15 and 21 foot-pounds with a torque wrench. Complete the installation of the water pump by performing steps two and three in reverse order.

7

Refill the cooling system with coolant and reattach the negative battery cable with a socket wrench. Start the engine and check for leaks in the cooling system.

The Jimmy is a mid-size sport utility vehicle made by GMC from 1983 to 2005. The models made from 1995 to 2005 belong to the second generation of the GMC Jimmy and are virtually identical to the Chevrolet Blazer. The 1998 GMC Jimmy has a water pump that the engine powers with a belt. It circulates coolant from the radiator to the engine to prevent the engine from overheating. You can access the water pump in the 1998 GMC Jimmy from the engine compartment near the cooling fan.

Instructions

1

Disconnect the cable to the negative terminal with a socket wrench to keep you from starting the engine while you replace the water pump. Place a sealable container under the radiator petcock and open the petcock. Allow the coolant to drain from the radiator into the container.

2

Rotate the belt tensioner pulley with a wrench to relieve the tension on the drive belt and remove the drive belt with a socket wrench. Disconnect the upper cover for the cooling fan and remove the pulley for the water pump. Release the clamp for the hose to the water pump and disconnect the hose.

3

Remove the retaining bolts for the water pump with a socket wrench and detach the water pump from the engine. Record the position of each retaining bolt as they may have different lengths. Discard the gasket for the water pump.

4

Apply a thin layer of 1052080 sealant to the threads of the retaining bolts for the water pump. Place a new gasket onto the new water pump and mount the water pump to the engine. Install the retaining bolts for the water pump and tighten them to 30 ft. lbs. with a torque wrench.

5

Attach the coolant hose to the water pump and secure it with the retaining clamps. Connect the pulley for the water pump and place the drive belt over the pulley. Allow the tensioner to contact the drive belt and install the upper fan cover with a socket wrench. Connect the negative battery cable and fill the radiator with coolant. Start the engine and check for leaks in the cooling system.

Jeep issued a recall on the 2000 Grand Cherokee Laredo in 2005 for fuel pump problems, according to Internet Auto Guide. Not a widespread recall, it only affected a few Laredos, but other fuel pump problems have arisen for some 2000 Jeep owners. The fuel pump pushes gas from the tank through the fuel line and into the engines injectors. Problems with the fuel pump cause little or no fuel to reach the engine, creating multiple problems.

Plastic Grommet Failure

A plastic grommet on the 2000 Laredo fuel pump module was not compatible with gasoline, which caused the grommet connectors to degrade and allow gasoline to leak out. Since the fuel pump sits near the exhaust system, gasoline leaking out of the fuel pump can land on the exhaust and create a fire hazard. The fuel pump came from a specific manufacturer and only affected 7,291 Chrysler vehicles---including the 2000 Jeep Grand Cherokee Laredo.

Fuel Pump Failure

According to the website Car Complaints, some 2000 Jeep Grand Cherokee Laredo owners have experienced fuel pump failure. Though no known specific cause for this problem exists as of 2010, gasoline leaking out of the fuel pump can cause it to work harder to push gasoline through the fuel line and possibly burn out. The only correction for this fuel pump problem involves replacing the fuel pump.

CMP Sensor Problems

The 2000 Jeep Grand Cherokee Laredo has had problems with the camshaft position (CMP) sensor. The Laredo uses the CMP sensor to synchronize the fuel through the fuel pump. When this sensor goes out or operates intermittently, the fuel pump will fail to push gasoline through the fuel line. The vehicle will stall during acceleration, run roughly, jerk or hesitate during operation or achieve low fuel mileage. The CMP sensor requires replacement to correct this fuel pump problem.

General Motors manufactured its LT1 engine from 1992 to 1997. This eight-cylinder 5.7-liter engine is in a variety of vehicles from General Motors such as the Chevrolet Camaro. The water pump in an LT1 engine cools the cylinder heads first before flowing around the rest of the engine. This allows the engine to run at a higher compression ratio, but also makes a faulty water pump more harmful to the engine.

Instructions

1

Disconnect the electrical wiring from the cooling fan. Remove the right cooling fan assembly with a socket wrench. Remove the left cooling fan assembly if your vehicle was made from 1996 to 1998.

2

Place a suitable container under the radiator. Remove the drain plug and knock sensor with a socket wrench. Drain the coolant from the radiator. Install the knock sensor and drain plug.

3

Remove the air cleaner and air intake duct with a socket wrench. Disconnect the upper and lower radiator hose from the water pump. Remove the heater hose from the water pump and throttle body.

4

Disconnect the electrical wiring from the coolant sensor. Loosen the retainers for the ignition coil bracket, and move the ignition coil out of your way. Remove the air pump bracket and disconnect the air pump, if necessary.

5

Unfasten the water pump mounting bolts with a socket wrench. Detach the water pump and discard its gasket.

6

Mount the new gasket to the new water pump and install the water pump. Torque the water pump mounting bolts to between 30 and 32 foot-pounds. with a torque wrench. Install the air pump if you removed it in Step 4.

7

Fasten the ignition coil bracket with a socket wrench, and attach the electrical wiring for the coolant sensor. Connect the heater hoses to the throttle body and water pump. Attach the radiator hoses to the water pump.

8

Install the air cleaner and air intake duct with a socket wrench. Replace the cooling fans that you removed in Step 1, and connect their electrical wiring. Fill the radiator with coolant.

9

Attach the cable to the negative battery terminal with a socket wrench. Start the engine and check for coolant leaks.

The Nissan D21 was a series of pickup trucks manufactured in the United States from 1986 to 1997. The 1992 models use fuel injection, which requires an electric fuel pump to pressurize the fuel system. The fuel pump in the 1992 Nissan truck is installed within the fuel tank, so you must lower the fuel tank to access the fuel pump. The fuel pump in these vehicles is generally not serviceable, so a fuel pump repair consists of replacing the faulty fuel pump.

Instructions

1

Remove the fuse for the fuel pump in the fuse box located under the dashboard on the drivers side. Start the engine and allow it to run until it stalls. Crank the engine for five seconds to ensure the fuel system is empty. Replace the fuse for the fuel pump.

2

Disconnect the cable from the batterys negative terminal with a socket wrench. This will ensure that you cant start the engine accidentally while repairing the fuel pump. Raise and support the vehicle on jack stands. Detach the electrical connector for the fuel pump assembly. Place a hose into the fuel tank and siphon the fuel into container approved for gasoline.

3

Detach the filler tube from the fuel tank with a socket wrench. Detach the fuel lines from the fuel tank including the fuel outlet hose, fuel return hose and ventilation hose. Detach the electrical connector for the fuel gauge unit. Support the fuel tank with a jack and remove the mounting bolts for the fuel tank. Disconnect the fuel tank from the vehicle and lower it to the ground with the jack.

4

Disconnect the retaining bolts for the ring on the fuel pump with a socket wrench. Discard the O-ring for the fuel pump and pull the fuel pump out of the fuel tank. Cover the hole in the fuel tank with a shop towel to prevent contamination of the fuel tank.

5

Install a new fuel pump and O-ring by reversing steps two through four. Start the engine and check for fuel leaks.

The Ford Econoline is a series of full-size passenger and cargo vans. The F-150 designation indicates the vehicle has a rated carrying capacity of at least 1/2 ton. The most common engine in a 1989 Ford Econoline F-150 is an 8-cylinder 5.0-liter engine. The oil pump on this engine is located on top of the engine near the front.

Instructions

1

Disconnect the mounting bolts from the oil pan with a socket wrench. Remove the oil pan from the engine. Detach the inlet tube from the oil pump and disconnect the screen assembly.

2

Remove the mounting bolts from the oil pump with a socket wrench. Pull the oil pump drive shaft from the body of the oil pump. Disconnect the oil pump assembly from the distributor socket and discard its gasket.

3

Fill the inlet and outlet ports of the new oil pump with engine oil and turn the oil pump drive shaft to distribute the oil through the pump. Align the oil pump drive shaft with the distributor shaft by rotating the oil pump drive shaft as required. Insert the oil pump drive shaft into the distributor socket. Position the new gasket on the pump body and insert the oil pump drive shaft into the pump body.

4

Connect the mounting bolts to the oil pump and tighten them to between 22 and 32 ft. lbs. with a torque wrench.

5

Install the screen assembly for the oil pump with a socket wrench and attach the inlet tube for the oil pump. Mount the oil pan and fasten the attaching bolts with a socket wrench.

Imagine that you have just finished filling the gas tank of your bright red Fiero and a few minutes after leaving the station your car sputters and shuts off as if it were out of gas. You hop out and look for leaking gasoline, but there is none to be found. You probably need to replace the fuel pump. The fuel pump moves the fuel from your tank to the engine, and when it stops working your car will shut off, as if it is out of gas. Learn how to remove a faulty fuel pump and you can avoid costly trips to the local mechanic.

Instructions

Removing the Fuel Pump

1

Remove the wire connected to the negative battery terminal. The negative wire will usually be black in color and the terminal often has a minus sign.

Continue to Step 2 if your engines fuel injection type is throttle body injection. Usually, V4 Fiero engines are this type.

Skip to Step 3 if your engine is of the multi-fuel injection variety. Usually, V6 Fiero engines are this type.

2

Pull the fuel pump fuse out of your fuseblock.

Start your car and run it until it shuts off. This will happen after the gas in the fuel line has been depleted. Attempt to restart it to make certain the fuel is gone. Check that the ignition is in the off position and reset the fuel pump fuse. Continue to Step 4.

3

Locate the fuel rail on top of the engine. Attach your fuel pressure gauge to the fuel rail valve. Wrap a rag around the fitting while you attach the gauge. Set the bleed hose of your gauge in to a gasoline-safe container. Open the valve and allow the gas to bleed from the fuel line. After the fuel has bled out, remove the gauge and cycle the ignition several times, with 10 seconds in between each cycle. After cycling the ignition, check for any leaks.

4

Lock the front tires of your vehicle in place with blocks. Initialize the emergency brake. Raise the rear of your car with a jack and place jack stands underneath.

5

Disconnect the fuel pump wire connector from the main wire harness located in the front of the engine compartment. Crawl under your Fiero and disconnect the fuel feed, fuel return, canister vent, the filler hose, and the breather hoses. Remove the heat shield covering the catalytic converter. Support the fuel tank with either a jack stand or another person and remove the support bracket and support straps. Lower the fuel tank with the front end of it tipped down.

6

The fuel pump is locked in to the fuel tank by a set of cams. Turn the inner ring clockwise using a brass punch and a hammer. After you have unlocked the fuel pump, carefully pull it out of the fuel tank.

The Chrysler Sebring is a series of mid-size cars in production since 1995. The 2001 model was the first of the second generation Sebrings, which was produced until 2005. The 2001 Chrysler Sebring has a mechanical water pump, like other modern vehicles. The engine drives the water pump with a belt, which circulates a mixture of water and antifreeze around the engine. The water pump in a 2001 Chrysler Sebring is attached to the front of the engine block.

Instructions

1

Allow the vehicle to sit overnight to ensure the coolant is not hot. Use a socket wrench to disconnect the cable to the negative battery terminal, so you dont accidentally start the engine.

2

Place a sealable container under the radiator and remove the drain plug for the radiator. Allow the entire contents of the radiator to drain into the container. Replace the drain plug and seal the container of coolant.

3

Use the socket wrench to remove the tensioner pulley for the timing belt.

4

Use the socket wrench to disconnect the brace for the alternator. Remove the mounting bolts for the water pump and disconnect the water pump. Discard the O-ring for the water pump.

5

Clean the O-ring mating surfaces on the water pump and the engine block with a shop towel to remove any remaining material from the O-ring. Place the new O-ring into position on the new water pump and install the water pump to the engine. Tighten the mounting bolts for the water pump to 117 in. lbs. with a torque wrench. Install the brace for the alternator and tighten its mounting bolts to 17 ft. lbs. Install the tensioner pulley for the timing belt.

6

Connect the cable for the negative battery terminal with a socket wrench. Refill the cooling system and start the engine. Check for leaks in the cooling system and repair as necessary.

Marine engines need to cool themselves internally to ensure consistent performance. The Evinrude Outboard does this by pumping water into the exhaust manifold. Over time, parts of the water pump fall victim to wear and tear, which reduces the effectiveness of the pump. Without a fully functioning water pump, the engine can overheat, leading to further damage.

Instructions

1

Open the Evinrude Outboards lower unit to gain access to the water pump. This is located at the top of the unit.

2

Place a drive shaft seal into the opening on top of the water pump housing, using a socket wrench to push the seal firmly into place. Cover the seal lightly in grease.

3

Put a new water tube grommet in the top of the pump housing.

4

Put gasket sealing compound on the replacement gasket for the impeller plate. The gasket fits onto the lower unit cover. The impeller plate fits on top of this.

5

Place the drive pin into the driveshaft. You may find a small amount of grease helps with this process.

6

Paint a thin coat of grease on the opening to the impeller housing and slide the impeller down onto the drive shaft. When done correctly, the groove in the impeller will slide over the drive pin.

7

Slip the pump housing over the impeller and twist the driveshaft by hand in a clockwise motion.

8

Place the water pump over the lower units studs. Add lock washer and nuts, tightening with a torque wrench to 75 inch-pounds.

Replacement Harley oil pumps must be primed after installation but before their first use in order to prevent air lock or cavitation. Essentially, air trapped inside the pump while it was out of the crankcase prevents oil from flowing and the engine quickly goes dry. It is a mistake one rarely makes twice since the engine may practically explode within a few hundred yards of leaving the garage on the first test ride. Oil pump manufacturers including S&S, Harley-Davidson and Sifton dryly note that substantial engine damage not covered under warranty may result from failing to prime an oil pump.

Instructions

1

Install the oil pump. Connect feeder and return lines. Fill the oil tank to correct level.

2

Remove check valve cover screw with a flat head screwdriver. Remove the check valve O-ring and spring by hand.

3

Remove the check valve ball with a mechanics magnet from inside the oil pump body. On a typical Harley oil pump the check valve cover screw is on top of the oil pump body.

4

Look inside the open check valve. The exposed cavity inside the oil pump should fill with oil within seconds.

5

Pour clean engine oil into the cavity if it remains empty and wait for five minutes.

6

Replace the check valve ball, spring, O-ring and screw. Put the motorcycle in "Neutral" and start the engine.

7

Confirm oil circulation with an oil pressure gauge and by removing the filler cap from the oil tank and watching oil return to the tank.

The Subaru Impreza is a compact car that Subaru has manufactured since 1993. The most common engine in a late-model Impreza is a 4-cylinder, 2.5-liter engine, which has the oil pump on the front of the engine. The function of the oil pump is to keep the engine lubricated by pumping oil through the engine. The primary portion of the oil pump replacement procedure is the removal of the additional components so you can access the oil pump.

Instructions

1

Remove the cable on the negative battery terminal with a socket wrench to prevent the engine from starting while you replace the oil pump. Place a container under the radiator drain and open the radiator drain cock. Allow the coolant to drain into the container and store the coolant for later use. Replace the radiator drain cock.

2

Raise the vehicle with a jack and support it with jack stands. Place a second container under the drain for the engine oil, then remove the drain plug with a socket wrench. Allow the oil to drain into the container, then fasten the drain plug.

3

Disconnect the covers for the timing belt with a socket wrench, then remove the timing belt assembly. Remove the bracket for the timing belt tensioner and detach the engine coolant pipe from the water pump. Disconnect the the water pump assembly from the engine. Remove the mounting bolts for the oil pump, then pry the oil pump from the engine block with a small pry tool. Discard the seal and O-ring for the oil pump.

4

Mount the new seal on the oil pump, then apply a thin layer of sealant to the oil pumps mating surface. Mount the new O-ring to the oil pump and install the oil pump to the engine block. Tighten the mounting bolts for the oil pump to 56 inch-pounds with a torque wrench.

5

Install the water pump to the engine with a socket wrench and attach the engine coolant pipe to the water pump. Install the timing belt assembly and the covers for the timing belt.

6

Lower the vehicle. Fill the vehicle with the proper amount of coolant and oil. Attach the cable to the negative battery terminal with a socket wrench.

A 1989 Chevrolet truck may be an S-10 or a member of the C/K series. The S-10 is a compact pickup truck, and the C/K series are full-size pickup trucks. These vehicles generally use an early form of fuel injection called throttle body injection. This type of fuel requires a low-pressure fuel pump that delivers fuel in the range of 9 to 13 pounds per square inch. A malfunctioning fuel pump typically requires you to replace the fuel pump.

Instructions

1

Loosen the fuel filler cap and remove the fuse for the fuel pump in the fuse box of the passenger compartment. Start the engine and allow it to stall. Crank the engine for three seconds and turn the ignition off. Replace the fuse for the fuel pump. Open the hood and disconnect the cable from the negative terminal on the battery with a socket wrench.

2

Siphon the fuel through the filler tube to drain the fuel tank into a gasoline-approved container. Raise the rear of the truck with the jack. Place jack stands under the frame and lower the vehicle onto the stands. Loosen the retaining clamp for the filler hose on the fuel tank, and disconnect the filler hose. Disconnect the fuel and vapor lines from the fuel tank, and disconnect the fuel hoses and electrical wiring from the fuel tank. Raise the jack to support the fuel tank, and remove the straps on the fuel tank. Lower the fuel tank slightly to gain access to the fuel sending unit. Disconnect the fuel lines and electrical wiring from the fuel sending unit. Lower the fuel tank to the ground.

3

Turn the cam locking ring on the fuel sending unit counterclockwise with tool No. J-24187 or J-36608. Remove the cam locking ring, and disconnect the fuel sending unit from the fuel tank. Discard the old gasket on the fuel tank. Pull the fuel pump from the bottom support and into the mounting tube without damaging the insulator or the fuel strainer. Pull the fuel pump out of its rubber connector.

4

Push the new fuel pump into the mounting tube of the fuel sending unit, and place the new gasket onto the fuel tank. Lower the fuel sending unit into the fuel tank without folding the fuel strainer.

5

Attach the cam locking ring on the fuel sending unit. Turn the locking ring clockwise with tool No. J-24187 or J-36608 until the locking ring locks into place. Connect the fuel tank and fill it with fuel. Connect the cable for the negative battery terminal, and check the fuel system for leaks.

On October 12, 2006, the National Highway Traffic Safety Administration (NHTSA) and DaimlerChrysler announced a fuel pump recall for 39,243 vehicles, including Dodge Cirrus and Stratus models manufactured between 1995-2000. Per the NHTSA, registered vehicle owners should have been notified by mail on or around Oct. 6, 2006.

Fuel Pump Defect

According to the NHTSA, the flapper valves in some of the Tigas fuel pump modules made between June 1 and Sept. 24, 2006, contained out-of-specification silicone material. The affected valves were sold under various brand names as "aftermarket for use in certain DaimlerChrysler vehicles."

Potential Danger

The use of out-of-specification silicone material caused excess swelling of the flapper valve restricting the flow of fuel to the fuel pump module. The restriction of fuel can potentially cause the engine to stall or lose power, which could result in an accident.

Remedy

Per the NHTSA, TI Automotive in October 2006 notified vehicle owners with Tigas models TU111, TU117, TU144 and TU174 where to bring their vehicles for a free replacement of the defective fuel pump modules. Concerned drivers may contact the NHTSA (888-327-4236) or TI Automotive (877-461-1834) to determine whether their vehicles could have been affected.

The fuel pump on a motor vehicle pumps the gasoline through the engine to be ignited and create power. The fuel must pass through a fuel filter to ensure that no contaminants reach the engine. The filter traps large particles of dust and debris, stopping them from affecting the engine.

Start Difficulties

The first sign of a malfunctioning fuel pump filter is difficulty starting the car. The filter will start to block the flow of gasoline into the engine. This is mainly caused by blockage or clogging, but can also occur from a break in the filter or a misinstallation. The problem will escalate over time if untreated, and what began as a difficult start that took several attempts will become a complete inability to start the engine. Once the filter hits this point of damage the only fix is to replace it.

Stalling

A significant indicator of a faulty fuel pump filter is the stalling of the engine during use. The stall will most likely occur on an upward or downward slope (depending on the placement in the car) when the fuel is being pushed through the filter rapidly. The stall happens because of an interrupted or inconstant flow of gasoline and feels much like the car does when running out of gasoline. At this point, however, the fuel pump filter may just need a quick repair or cleaning.

Acceleration

The fuel pump filters earliest indicator of problems manifests as stunted acceleration. If the car starts running sluggishly or unresponsively it will mean the fuel pump is either off alignment or in the beginning stages of a clog. There is a good chance at this point that a simple fuel injector cleaner solution may fix this problem and the vehicle will start running efficiently again.

The Ford E-Series, or Econoline, is a line of full-size cargo and passenger vans. The number indicates the carrying capacity, with the 250 designator indicating a 3/4 ton carrying capacity. The 1991 Ford Econoline 250 was available with several eight-cylinder engines, all with fuel injection. This vehicle uses a high-pressure fuel pump that is part of the fuel sender assembly located in the fuel tank. You must remove the fuel tank to service the fuel pump in a 1991 Ford Econoline 250.

Instructions

1

Disconnect the electrical connection for the fuel pump relay and start the engine. Run the engine until it stalls. Crank the engine for five seconds to ensure the fuel system is empty. Connect the electrical connection for the fuel pump relay.

2

Disconnect the cable on the negative battery terminal with a socket wrench. Use a floor jack to raise the van onto jack stands. Siphon the fuel out of the fuel tank through the filler cap opening. Detach the electrical connections for the fuel sending unit and fuel pump. Disconnect the fuel lines from the fuel tank. Place a piece of wood on a floor jack and move the floor jack under the fuel tank. Raise the floor jack to support the fuel tank. Loosen the retainers for the filler tube and the fuel tank straps. Lower the floor jack and remove the tank from the vehicle.

3

Clean the surface of the fuel tank around the fuel sender assembly with a shop rag. Turn the locking ring on the fuel sender assembly counterclockwise with a hammer and brass drift punch. Remove the locking ring and remove the fuel sender assembly from the fuel tank. Discard the gasket for the fuel sender assembly.

4

Clean the mounting flange on the fuel tank and apply a thin layer of grease with Ford specification ESA-M1C75-B. Place the new gasket into the groove on the fuel tank. Install the fuel sending unit into the fuel tank, and align the tabs on the fuel sending unit with the slots in the fuel tank.

5

Tighten the locking ring for the fuel sending unit clockwise until it stops. Install the fuel tank. Connect the electrical connectors and fuel lines for the fuel sending unit. Lower the vehicle. Fill the fuel tank with fuel. Connect the cable for the negative battery terminal.

The GMC Jimmy is a mid-size sport utility vehicle made by General Motors from 1983 to 2005. The 2001 model is a second generation Jimmy, which has a 6-cylinder 4.3-liter engine with sequential fuel injection. This type of fuel injection uses a high-pressure fuel system requiring an electric fuel pump. The fuel pump in the 2001 GMC Jimmy is located within the fuel tank, so you must disconnect the fuel tank to replace the fuel pump.

Instructions

1

Disconnect the cable for the negative battery terminal with a socket wrench to prevent the accidental discharge of fuel. Open the filler cap for the fuel tank to relieve the fuel tank pressure. Wrap a shop rag around the pressure fitting on the inlet fuel pipe and install a pressure gauge to the pressure fitting. Place the bleed hose of the pressure gauge into a gasoline container and open the valve for the pressure gauge. Allow the fuel in the fuel system to drain into the gasoline container and disconnect the pressure gauge from the pressure fitting.

2

Drain the fuel tank by siphoning the fuel into a gasoline container with a hose. Support the fuel tank with a floor jack and disconnect the filler neck for the fuel tank with a socket wrench. Detach the skid shield and retaining straps from the fuel tank. Remove the electrical connections and fuel lines from the fuel pump. Disconnect the the mounting bolts for the fuel tank with a socket wrench and lower it from the vehicle with the floor jack.

3

Turn the locking ring on the fuel sending assembly counterclockwise with a spanner wrench. Remove the locking ring and disconnect the fuel sending assembly from the fuel tank. Separate the fuel pump from the fuel sending assembly.

4

Replace the seal around the opening in the fuel tank. Install the new fuel pump by performing steps two and three in reverse order. Tighten the mounting bolts for the fuel tank to 33 ft. lbs. with a torque wrench.

5

Connect the cable for the negative battery terminal with a socket wrench. Fill the fuel tank with fuel, start the engine and check the fuel system for leaks.

The Generation II LT is a series of eight-cylinder engines manufactured by General Motors. The LT1 version has a displacement of 5.7 liters and was in production from 1992 to 1997. The LT1 appears in high-performance General Motors cars made during this period, such as the Corvette, Camaro and Firebird. The water pump for the LT1 circulates coolant to the cylinder heads, which then flows through the engine block. A faulty water pump can cause the engine to overheat even when it has coolant.

Instructions

1

Disconnect the cable from the negative battery terminal with a socket wrench. Detach the electrical connector from the cooling fan. Disconnect both cooling fan assemblies.

2

Position a drain pan under the radiator and disconnect the knock sensor. Remove the drain plug for the radiator and allow coolant to drain into the drain pan. Replace the drain plug and connect the knock sensor.

3

Disconnect the air filter and air intake duct with a socket wrench. Detach the radiator hoses and heater hoses from the water pump. Remove the heater hoses from the throttle body. Detach the electrical connector from the coolant sensor.

4

Release the retainers on the bracket for the ignition coil, and push the ignition coil aside. Disconnect the air pump and its bracket with a socket wrench, if your vehicle is so equipped.

5

Remove the mounting bolts for the water pump with a socket wrench, and disconnect the water pump. Discard the gasket for the water pump, and clean the mating surfaces for the gasket with a clean shop towel.

6

Install the new water pump and gasket. Tighten the mounting bolts for the water pump to between 30 and 32 ft. lbs. with a torque wrench. Connect the air pump and its bracket, if your vehicle is so equipped. Place the ignition coil and bracket into their proper position, and fasten their mounting bolts with a socket wrench.

7

Connect the electrical connector for the coolant sensor. Attach the heater hose to the throttle body. Connect the heater hose and radiator hoses to the water pump. Connect the air intake duct and the air cleaner with a socket wrench. Install the cooling fans and attach their electrical connectors.

8

Fill the radiator with coolant, and attach the cable to the negative battery terminal with a socket wrench. Start the engine and check for coolant leaks.