When servicing fuel pumps and fuel modules, it pays to look beyond the basics. Of course, solid installation and repair skills are essential for any technician who wants to do the job right the first time. But problems that can crop up when installing fuel pumps and fuel modules aren’t always obvious – and overlooking them can result in unwanted comebacks.

Here are some tips to help ensure that every fuel pump and fuel module installation or repair is a successful one:

Inspect the electrical connector for signs of damage
For a variety of reasons, some vehicles may be prone to electrical connector failures. These failures often can be seen as overheated terminals and wiring, so it’s essential to replace the mating vehicle wiring when replacing the fuel module or pump on these vehicles. Otherwise, the new service part can fail prematurely. If a new wiring pigtail is included with the module or fuel pump kit, be sure to install it. The new pigtail may often look different than the original part, but the improved electrical connector can easily be installed by using the parts and following the detailed instructions included in the kit.

Examine the fuel tank and fuel module bucket for contamination
Fuel pump and module failures can often be attributed to contaminants found inside the fuel tank or fuel module. These contaminants can cause excessive wear of the fuel pump, plug strainer and filters. If contamination is found, the fuel tank should be drained and cleaned before installing the new part. Also look for rust inside the tank or bucket of the fuel module, which indicates water is in the fuel delivery system. Metal fuel lines and fuel rails should be examined for signs of internal rust or corrosion and replaced as needed. Contaminants can be drawn into a vehicle’s fuel system if the evaporative emissions system is not operating properly. It’s essential to determine the cause or source of the contamination and correct it before installing the new part.

Install the float arm onto the level sensor of the fuel module
New fuel module service kits may come with the float arm assembly detached from the fuel level sensor. It’s important to install the float arm onto the level sensor prior to installing the fuel module into the tank. Failure to install the float arm will cause the fuel level sensor to operate incorrectly and create a customer complaint. Detailed instructions on how to properly install the float arm onto the level sensor are included in the fuel module service kit.

Replace the fuel filter and strainer when installing a new fuel pump or fuel module
Most fuel module kits include new strainers with the fuel module assembly. These strainers can be internal, external or both depending on the fuel module design. If a new strainer is not included with the fuel pump, one should be obtained and installed on the pump prior to installation into the vehicle. Be sure it’s correctly seated so contaminants can’t pass around it. Replace the fuel filter on vehicles that have serviceable fuel filters. Many late-model fuel modules now incorporate the fuel filter into the fuel module, so the filter is replaced when the module is replaced.

Delphi offers a broad array of fuel pumps, fuel level sensors and other fuel system components for the aftermarket, all developed and engineered based on Delphi’s decades of experience with original equipment (OE) applications. In particular, Delphi’s fuel pumps have a reputation for quiet, durable performance with little flow or pressure variation in hot fuel situations – features proven in competitive studies. For more information visit iam.delphi.com.

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