How to Install an Inline Fuel Pump
- 1). Raise the rear of the vehicle and support it on jack stands. Locate a position for the fuel pump close to the fuel tank, free of the heat from the exhaust and clear of the axle's movement. The best location is generally on the inside of the frame rail just forward of the tank or on the body section forward of the axle and what would be the backside of the rear seat upright. The pump must be protected from road damage, heat and moving parts. The fuel line should not pass over the exhaust.
- 2). Mark and drill the holes for the fuel pump and the fuel filter if the pump is a frame-mount type. Install the bolts and nuts and tighten them with the socket wrench.
- 3). Bend the fuel line in preparation for installation. Make sure that the stick of fuel line is the same size as that in use on the vehicle. A professional would not use more than 3 inches of fuel line for connection purposes. The rest of the line must be metal to prevent the possibility of leaks. Bend the fuel line with the bending tool so the fuel line will be capable of coupling to the fuel line from the fuel tank with a 1-inch gap. The gap is spanned with a fuel line hose. The other end must route properly to couple to the fuel pump with the same gap. The fuel line running forward must be cut to couple to the fuel pump in the same manner.
- 4). Locate the spot for the fuel filter and fuel pressure regulator. The regulator should be on the firewall where the fuel line enters the compartment. The fuel line should couple to the regulator with a small gap. Mount the regulator by marking and drilling two holes and mounting the bolts and tightening securely with a socket wrench.
- 5). Plan the metal fuel line routing to the carburetor so it ends up with a small gap between the line and the inlet to the carburetor. For fuel-injected vehicles, just place the fuel pressure regulator in line at the firewall. Cut the line with the tubing cutter and install the line with a small piece of fuel line to span the gaps. Install the hose clamps and tighten securely with a screwdriver.
- 6). Install the pre-bent and cut fuel line from the fuel pump to the fuel line, running forward first. Cut a piece of 3-inch fuel line. Push the fuel line on the pump and secure it with a hose clamp. Insert the fuel line running forward into the opposite end of the hose. Install a clamp and tighten.
- 7). Push the 3-inch piece of fuel line onto the inlet side of the fuel pump. Install a clamp and tighten. Use the tubing cutter to cut the fuel line from the tank to the fuel pump inlet. Before you cut, make sure the line will be long enough to reach the pump. Fuel will be spilled during this process, so it must be done quickly. Have the clamp loosely on the fuel line hose. As soon as it is cut, insert the metal fuel line into the fuel hose and tighten the clamp.
- 8). Install fuel line support brackets or loops to secure the fuel line. Install the supports with self-tapping screws supplied with the supports. Install the fuel pump switch in a satisfactory position on the dash.
- 9). Connect a wire to the fuel pump's red wire, using a butt terminal connector. Crimp it with the wire crimpers. From this point on, crimp all terminal connectors. Run the wire along the frame, using wire supports, to the electrical fuel pump switch. Connect the wire to the back of the switch with a post connector. Using a post connector on the other side of the switch, run a wire to the inline fuse. Using butt connectors, from the other end of the inline fuse to the fuse block, connect the wire to the accessory fuse using a terminal adapter.
- 10
Connect the black lead from the fuel pump to another piece of wire with a butt connector. Run the wire to a good ground on the frame using a post terminal connector.
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