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A cars fuel injection system supplies fuel to the engine. In order to get optimum performance from your vehicle, the fuel must flow at a steady pressure. Regulators control the fuel flow, making sure it is consistent. Like other mechanical parts, regulators can break down and require replacement. Symptoms of a faulty regulator include lower gas mileage, excess smoke from exhaust pipes and leaking oil from the engine. Replacing a fuel regulator can be a difficult task for inexperienced owners, but if you have basic car repair experience, you can save money and replace it yourself.

Instructions

1

Relieve the pressure in the fuel tank by opening the gas cap. Open the hood of the car and separate the cable from the negative battery terminal. Pull out the cushion on the rear seat. Remove the screws on the service hole cover and take off the cover.

2

Disconnect the electrical wiring from the fuel pump assembly. Use the fuel line disconnect tool to unplug the fuel outlet pipe from the fuel pump bracket. Unscrew the retaining screws for the fuel pump bracket with the socket wrench. Pull off the return hoses from the bracket. Take the assembly out of the fuel tank.

3

Use the socket wrench to remove the fuel suction support from the fuel pressure regulator. Separate the fuel filter from the regulator. Find and remove the O-ring from the regulator.

4

Apply a thin coating of gasoline to the O-ring and insert it into the new fuel pressure regulator. Attach the regulator to the fuel filter. Connect the fuel suction support to the regulator using the wrench.

5

Replace the fuel pump assembly in the fuel tank and reconnect the hoses to the fuel pump bracket. Attach the retaining screws to the fuel pump bracket and connect the fuel outlet pipe to the fuel pump bracket.

6

Reattach the wiring for the fuel pump assembly. Reinstall the service hole cover with the socket wrench. Reinstall the rear seat cushion and reconnect the negative battery cable.

The fuel filter on a 1985 Buick Century is designed so that gasoline flowing to the engine is free of harmful debris. The fuel pump, located inside the gas tank, has a built-in strainer. This keeps large debris from leaving the tank but smaller debris and sediment can get past the strainer. If not changed, the small debris will eventually clog the fuel filter; this can affect gas mileage and engine performance. Fuel filters should be changed annually or every 30,000 miles.

Instructions

Remove the Fuel Filter

1

Open the hood and locate the fuse panel. Open the fuse panel and locate the fuel pump relay. Pull it out by hand.

2

Start the engine and let it run. The engine will stall once the fuel system has depressurized. Turn off the engine and replace the relay back in to the fuse panel. Close the fuel panel.

3

Crawl under the car behind the driver-side rear wheel well and look for the fuel filter. The fuel filter is canister-shaped with a fuel line entering and exiting the filter; it will be in a mounting bracket on the frame rail. You can also trace the fuel line from the gas tank to find the fuel filter.

4

Place a drain pan under the fuel filter to catch any gas in the fuel lines or the fuel filter.

5

Disconnect the inlet fuel line from the fuel filter by pinching the tab on the quick-disconnect fitting and pull the fuel line off the fuel filter. If the fuel line is held on by a hose clamp, loosen the clamp with a screwdriver. Remove the outlet fuel line the same way.

6

Use a socket wrench to loosen the bolt on the mounting bracket and slide the fuel filter out of the bracket. Discard the fuel filter.

Install the Fuel Filter

7

Slide the new filter in the bracket. Make sure the arrow on the fuel filter is pointing toward the front of the car. The arrow designates the direction of fuel flow. Tighten the bracket bolt with the socket wrench. The fuel filter should be tight in the bracket.

8

Push the inlet fuel line onto the fuel filter until it clicks in place. If held on by hose clamps, push the fuel line over the fitting on the fuel filter. Slide the hose clamp over the hose and fitting and tighten it with a screw driver. Do the same for the outlet fuel line.

9

Start the engine and let it to run for at least 5 minutes.

10

Check the fuel filter and fuel lines to make sure there are no gas leaks.

A fuel injector delivers fuel to engine cylinders in a specific sequence. Modern fuel injectors are typically electronically controlled, but older engines used mechanical fuel injection. For example, the large diesel engines in heavy Ford trucks made from 1987 to 1996 used mechanical injection. Removing the injectors in these vehicle also requires you clean the injection system due to the deposits left by diesel fuel.

Instructions

1

Clean the nozzle of each fuel injector and the surrounding area with clean engine oil to keep debris out of the engine when you remove the injectors. Clean the connections for the fuel lines on the injectors. Blow the injectors dry with an air compressor.

2

Release the retaining clamps for the fuel lines on the injectors. Detach the high-pressure fuel lines and the leak-off tees from the injectors. Push the fuel lines out of the way. Cover the open fuel lines with caps to keep debris out of the fuel system.

3

Turn the injectors counterclockwise with a socket wrench to loosen them from the engine. Pull the injectors from the engine with the washer still attached. Cover the injector nozzles and fuel openings with plastic caps to prevent fuel contamination.

4

Store the injectors in numbered holders as you remove them. This allows you to replace the injectors into their correct cylinder.

The Pontiac Bonneville is a series of cars manufactured by the Pontiac division of General Motors since 1957. The 1992 model is the first of the eighth generation of the Pontiac Bonneville, and represents a major redesign over the previous generation. The standard engine in the 1992 Pontiac Bonneville was a six cylinder, 3.8 L engine with sequential fuel injection. You must remove the fuel rail to access the fuel injectors for this vehicle.

Instructions

1

Disconnect the cable for the negative battery terminal with a socket wrench to avoid the accidental discharge of fuel. Open the filler cap on the fuel tank to relieve the pressure in the fuel tank.

2

Remove the cap for the fuel pressure connection on the fuel rail and wrap a shop towel around the connection. Attach fuel pressure valve J 34730-1A to the fuel pressure connection. Place the open end of the pressure valves bleed hose into a container approved for gasoline open the valve to relieve the pressure in the fuel system. Disconnect the pressure valve and replace the cap for the fuel pressure connection.

3

Disconnect the fuel lines for the fuel rail with a back-up wrench and discard the O-rings. Detach the fuel return line from the pressure regulator. Disconnect the wiring for the ignition coil and electrical connectors for the fuel injector. Remove the mounting bolts for the fuel rail with a socket wrench and disconnect the fuel rail assembly by pulling on both sides of the fuel rail with equal force.

4

Cover the open fuel lines with masking tape to keep debris out of the fuel lines. Release the retaining clips for the fuel injector and discard them. Detach the fuel injector from the fuel rail. Discard all of the O-rings on the fuel injectors.

5

Apply a thin layer of engine oil to the new O-rings. Install the O-rings onto the new fuel injectors and place the new retainer clip onto the fuel injector. Place the fuel injectors into the sockets on the fuel rail so the electrical connections on the fuel injectors face outwards. Lock the retainer clips for the fuel injectors.

6

Install the fuel rail by performing steps 3 and 4 in reverse order. Fasten the cap for the fuel tank and connect the cable on the negative battery terminal with a socket wrench. Turn the ignition on for two seconds to pressurize the fuel system, then turn the ignition off for 10 seconds. Turn the ignition back on and check for fuel leaks.

Chrysler uses the Jeep marquee for its line of off-road and sport utility vehicles. The 1997 models include the Cherokee, Grand Cherokee and Wrangler. These vehicles use multi-port fuel injection, requiring the fuel pump to deliver highly-pressurized fuel. The fuel pump in a 1997 Jeep is located under the vehicle, requiring you to raise the vehicle to service the fuel pump. These fuel pumps are not user serviceable, so you must replace a malfunctioning fuel pump.

Instructions

1

Disconnect the cable to the negative terminal on the battery with a socket wrench. This will prevent the accidental discharge of fuel while you replace the fuel pump. Siphon fuel from the fuel tank into a gasoline container until the fuel tank is below 1/4 full.

2

Block the front wheels with chocks to prevent the accidental movement of the vehicle. Raise the vehicle with a floor jack and support it on jack stands. Disconnect the fuel hoses from the fuel sending unit.

3

Disconnect the electrical wiring from the fuel sending unit. Turn the locking ring from the field sending unit counterclockwise with a hammer and brass punch. Remove the locking ring and detach the field sending unit from the vehicle. Remove and discard the O-ring on the fuel tank.

4

Remove the fuel filter from the fuel sending unit and discard it. Detach the electrical wiring from the fuel pump. Release the clamp on the fuel line for the fuel pump and disconnect the fuel line. Remove the nut for the top mounting bracket of the fuel pump with a socket wrench. Detach the fuel pump from the rest of the fuel sending unit.

5

Replace the fuel filter on the fuel pump and install the fuel pump into its top mounting bracket with a socket wrench. Connect the electrical wiring and fuel lines to the fuel pump. Place a new O-ring on the fuel tank.

6

Place the locking ring onto the fuel sender unit and turn it clockwise with the hammer and brass punch until it reaches to the stop on the fuel tank. Connect the fuel lines and electrical wiring for the fuel tank. Lower the vehicle with the floor jack and fill the fuel tank with fuel. Start the engine and check for fuel leaks.

The Mazda 626 is a series of cars manufactured by Mazda for the export market from 1979 to 2002. The 1991 Mazda 626 was a mid-size car, and the LX designator indicates a trim level in the United Kingdom. The engine for the 1991 Mazda 626 uses fuel injection, which requires the fuel pump to deliver pressurized fuel. The fuel pump for this vehicle is accessible from the rear passenger compartment.

Instructions

1

Start the engine, and remove the relay connector under the left side of the instrument panel. Allow the engine to stall, and turn the ignition switch off. Connect the relay connector.

2

Disconnect the cable for the negative battery terminal with a socket wrench. Press the clip on each end of the rear seat to release the cushion, and remove the rear seat cushion. Detach the electrical connector for the fuel pump assembly. Remove the screws on the access cover for the fuel pump assembly, and open the access cover.

3

Detach the fuel lines from the fuel pump assembly, and remove the mounting screws on the fuel pump assembly with a socket wrench. Discard the old gasket for the fuel pump assembly. Disconnect the electrical connector for the fuel sending unit, and remove the mounting nuts for the fuel sending unit. Disconnect the fuel sending unit from the fuel pump.

4

Attach the fuel sending unit to the new fuel pump, and fasten the mounting nuts for the fuel sending unit with a socket wrench. Connect the electrical connector for the fuel sending unit, and place a new gasket on the fuel tank. Install the fuel pump assembly into the fuel tank, and fasten the mounting screws for the fuel pump assembly. Attach the fuel lines to the fuel pump assembly.

5

Replace the access cover, and fasten the mounting screws for the access cover with a socket wrench. Connect the electrical connector for the fuel pump assembly, and replace the rear seat cushion. Connect the cable for the negative battery terminal, and start the engine. Check the fuel system for leaks.

The 1996 Geo Metro has a four-cylinder 1.3 liter engine that uses fuel injection to deliver fuel to the engine at high pressure. The fuel pump is in the fuel tank, which means you must disconnect the fuel tank before you can replace the fuel pump. Experienced home mechanics should be able to do the job in several steps.

Instructions

1

Loosen the fuel tank cap to relieve the pressure in the fuel tank. Disconnect the fuse for the fuel pump relay in the engine compartment. Run the engine until it stalls, then engage the engine to ensure you have completely relieved the pressure in the fuel system.

2

Disconnect the negative battery cable with a socket wrench to prevent accidental sparking from the battery.

3

Siphon the fuel through the filler tube of the fuel tank into a container approved for gasoline. Detach the electrical connector for the fuel pump and fuel sending unit.

4

Raise the vehicle with a floor jack and support it on jack stands. Release the clamps on the filler neck and disconnect the filler neck from the fuel tank. Disconnect the clamp from the inlet hose on the fuel filter and detach the inlet hose from the fuel filter.

5

Disconnect the clamps for the fuel lines to the fuel tank and detach the fuel lines from the fuel tank. Support the fuel tank with a transaxle jack, and remove the mounting bolts for the fuel tank with a socket wrench. Disconnect the fuel tank and lower it from the vehicle with the transaxle jack.

6

Release the clamps for the fuel lines on the fuel pump assembly and detach the fuel lines from the fuel pump assembly. Disconnect the attaching screws for the fuel pump assembly with a socket wrench and remove the fuel pump assembly from the fuel tank.

7

Remove the mounting screws for the fuel pump. then detach the electrical connector for the fuel pump. Disconnect the fuel pump from the rest of the fuel pump assembly.

8

Perform steps 2 through 4 in reverse to complete the fuel pump installation. Fill the fuel tank and connect the negative battery terminal with a socket wrench. Turn the ignition switch to the ON position. Start the engine and check for fuel leaks.

The heat applied to a fuel tank seam during tank construction can cause failure along the welded seam. Repairing the broken tank seam will stop fuel from leaking and causing a fire hazard. Welding the cracked seam will permanently seal the seam. Performing the weld safely requires eliminating fire hazards--including fuel fumes remaining in the tank--and using the proper tools to perform the repair.

Instructions

1

Drain the fuel from the plastic tank. Remove the tank from the vehicle.

2

Pour a mixture of dishwashing soap and water into the top of the fuel tank. Slosh the mixture around, then dump the soapy solution from the tank. Repeat the procedure two more times to remove fuel residue and fumes from the tank.

3

Plug in the plastic welding gun. Set the welder to the temperature designated on the heat requirement chart affixed to the welder box. Turn on the welder.

4

Wipe the cracked seam with a clean rag soaked in the soap solution. Rinse the seam with clean water. Allow the seam to dry.

5

Run the point of a triangle file along the cracked seam to create a 1/16 inch V-groove.

6

File the raised edges left by the file from the area with 400-grit sandpaper.

7

Place the tip of the plastic welder on one end of the cracked plastic seam. Push a plastic filler rod into the top socket of the welding tip as you slowly pull the welder along the seam. Pull the plastic welder away from the fuel tank when you reach the opposite end of the cracked seam, leaving the excess filler rod attached to the tank.

8

Cut the excess filler rod from the tank with a pair of wire cutters.

9

Allow the repaired seam to cool before installing the tank back into the vehicle.

The Chrysler 3.3 engine has been used in a variety of automobiles, from vans to trucks and small passenger vehicles. Its accompanying fuel system has been improved several times over the years and can vary greatly depending on the particular vehicle. With these differences in mind, there are several fuel components that remain the same in all vehicle types, providing the 3.3 engine with power and performance.

Fuel Injection System

When the 3.3 engine was first introduced in 1990, it featured a fuel injection system. This improved acceleration and engine performance in the Chrysler Town & Country, the Dodge Caravan, Chrysler New Yorker and Chrysler Imperial. The fuel injection system includes a fuel pump, fuel pressure regulator, fuel sensors and an engine control module. Fuel injection eliminates the need for a carburetor in the Chrysler 3.3 s fuel system.

Improved Intake System

Improved fuel intake goes along with the fuel injection system, which increased the Chrysler 3.3s horsepower. A variable intake system was implemented in 2001 which further increased horsepower and torque. This system functions by varying the length of the intake tract which can also improve fuel economy. Gas mileage is particularly important for family vehicles which may end up on the lower end of miles per gallon ratings, such as minivans.

Fuel Tank and Filters

The type of gas tank in the Chrysler 3.3 engine depends on the model of vehicle. For larger Chrysler vehicles, such as minivans, the gas tank size can be as large as 20 gallons. With smaller models, like the Chrysler Concorde, fuel tanks top out at 17 gallons. Each gas tank has fuel lines which feed into the vehicles fuel injection system, along with fuel filters to keep debris and other large particles from entering the engine and causing damage.

The Mazda B-Series is a line of pickup trucks manufactured by Mazda Motor Corporation from 1961 to 2006. The number in the series indicates the displacement of the engine, so a Mazda B-4000 has a 4-liter engine. This engine utilizes electronic fuel injection, which requires a highly pressurized fuel system. The fuel pump in a Mazda 4000 is mounted to the fuel tank, so the tank must be removed to service the pump.

Instructions

1

Open the cap on the fuel tank to relieve pressure. Connect pressure gauge T80L-9974-B to the pressure relief valve on the fuel supply manifold. Place the open end of the bleed hose on the pressure gauge into a gasoline container. Open the pressure gauge to relieve the pressure in the fuel system. Disconnect the pressure gauge from the pressure relief valve.

2

Disconnect the cable from the batterys negative terminal to prevent accidental sparking. Siphon as much fuel as possible with a hose from the fuel tank into a gasoline container. Raise the vehicle with a jack and mount it on jack stands. Remove the mounting bolts for the skid plate with a socket wrench and remove the skid plate.

3

Detach the fuel lines from the fuel tank and disconnect the electrical connections to the fuel pump. Support the fuel tank with a floor jack and remove the mounting bolts for the fuel tank straps with a socket wrench. Disconnect the fuel tank straps without deforming the fuel tank. Detach the fuel tank and lower it from the vehicle with a floor jack.

4

Clean the fuel tank around the fuel pump with a shop towel to prevent contamination of the fuel when you remove the fuel pump assembly. Turn the locking retainer ring for the fuel pump assembly with a socket wrench and locking ring adapter. Remove the locking retainer ring and pull the fuel pump assembly from the fuel tank without damaging the float arm or fuel filter. Discard the mounting gasket for the fuel pump assembly and clean the mounting surface for the fuel pump assembly.

5

Install the new fuel pump and mounting gasket by performing Steps 2 through 4 in reverse. Tighten the locking ring for the fuel pump assembly by turning it clockwise until it locks into place. Fill the tank with gasoline and check the fuel system for leaks.

The Chevrolet Suburban has been in continuous production since 1935. The 2002 model was a sport utility vehicle that also had other marketing names such as the GMC Yukon and Cadillac Escalade. This vehicle had several choices of engines, all of which had fuel injection. The fuel pump in the 2002 Chevrolet Suburban installs into the fuel tank. You must theore remove the fuel tank from the vehicle to install the fuel pump.

Instructions

1

Disconnect the cable on the negative terminal of the battery to avoid starting the engine accidentally. Remove the filler cap for the fuel tank to relieve the pressure in the fuel tank. Wrap a shop towel around the fuel pressure fitting on the fuel rail and attach a fuel pressure gauge to the fitting. Connect the bleed hose to the pressure gauge and place the open end of the bleed hose into a container approved for gasoline. Open the fuel pressure gauge to relieve the pressure in the fuel system. Remove the fuel pressure gauge from the fitting.

2

Place one end of a hose into the filler tube of the fuel tank and place the other end into the gasoline container. Siphon as much fuel as possible from the fuel tank into the container.

3

Disconnect the filler pipe and fuel lines from the fuel tank. Support the fuel tank with jack stands and remove the bolts for the fuel tank straps with a socket wrench. Disconnect the fuel tank straps and lower the fuel tank slightly so you can disconnect the harness clip from the cross member and the electrical connections from the fuel tank. Lower the fuel tank completely and remove it from the vehicle.

4

Turn the retaining ring for the fuel sender assembly counterclockwise with a fuel tank sending wrench. Remove the retaining ring, and detach the fuel sender assembly from the fuel tank. Discard the gasket on the fuel tank. Pull the fuel strainer from the fuel sender assembly and discard the strainer.

5

Detach the electrical connector for the fuel pump. Release the retaining clip for the fuel sensors electrical connector and detach the fuel sensors electrical connector. Release the retaining clip for the fuel level sensor and remove the fuel level sensor.

6

Install the new fuel pump and gasket by reversing steps two through five. Tighten the bolts for the fuel tanks retaining straps to 30 ft. lbs. with a torque wrench. Tighten the bolts for the cross member to 37 ft. lbs. Fill the fuel tank and replace its filler cap. Connect the cable for the negative terminal on the battery with a socket wrench. Turn the ignition on for two seconds, then turn it off for 10 seconds to pressurize the fuel system. Turn the ignition back on and check for fuel leaks.

International Harvester made an eight-cylinder 7.3-liter diesel engine from 1988 to 1992. The engine was typically used in large Ford trucks from this period, such as the F250 3/4 ton pickup truck. The International 7.3-liter engine uses direct fuel injection.. The injectors for this engine do not require electronic control and are easily accessible, making it easy to replace them.

Instructions

1

Clean the fuel injector nozzles and fittings with fuel oil to prevent fuel contamination when you replace the injectors. Blow the area dry with an air compressor.

2

Release the retaining clamps on the fuel line to the fuel injector. Fetach the fuel lines from the fuel injectors with a flare nut wrench. Disconnect the run-off tees from the fuel injectors and discard their gaskets. Move the fuel lines out of your way, and cover the ends of the fuel injectors with plastic caps to keep dirt out of the injectors.

3

Turn the fuel injector counterclockwise with a socket wrench. Pull the injector from its bore, and discard the copper gasket. Clean the injector bore with special tool T83T-9527-A, and blow out the loose debris with an air compressor.

4

Dab a small amount of anti-seize compound on the nozzle of the new fuel injector, and mount a copper gasket to the injector. Install the fuel injector into its bore, and tighten it to 33 foot-pounds with a torque wrench.

5

Mount new gaskets to the run-off tees, and connect the run-off tees to the fuel injector. Connect the fuel lines to the fuel injector with a flare nut wrench, and attach the retainer clamps to the fuel injector. Start the engine and check for fuel leaks.

Chevrolet is one the leading manufacturers of quality, American-made trucks. If you have a job to do, you want to be able to rely on the power of your truck and that it can handle the job. The Chevrolet pickup can handle most any job unless the fuel system fails. Troubleshooting the fuel system on your Chevy truck is not as tough as you might think. If you decide to tackle the troubleshooting of the fuel system, you might find the issue and fix the problem yourself.

Instructions

1

Open the hood of your truck.

2

Direct your assistant to sit in the drivers seat and be prepared to turn the key on and off when you prompt.

3

Remove the fuel line from the fuel injector unit with the screwdriver set. The fuel injector unit is located on the top of the motor. You will recognize the fuel line because you can follow it back to the gas tank.

4

Have your friend turn the key on and off quickly. If you do not see fuel coming out of the fuel line, then you need to move on to the fuel filter.

5

Follow the fuel line back from the engine compartment until you find the fuel filter located under the truck. Remove the line coming into the filter from the gas tank side with the tubing wrench set. Ask your helper to turn the key on and off again. If you have fuel flow, then you need to change the fuel filter. If you do not see fuel, then you need to replace the fuel pump in the gas tank.

The Pontiac Sunfire is a compact car, manufactured by Pontiac from 1995 to 2005. This vehicle uses Pontiacs J platform, and has a four-cylinder 2.2-liter engine with sequential fuel injection. Each cylinder has its own fuel injector, which delivers pressurized fuel to the cylinder in a precise sequence. The fuel injectors are generally not serviceable, so the repair procedure consists of replacing the faulty injectors.

Instructions

1

Disconnect the cable from the negative battery terminal with a socket wrench to avoid the discharge of fuel while installing the fuel injectors. Open the filler cap on the fuel tank to relieve the pressure in the fuel tank.

2

Wrap a shop towel around the fuel pressure port on the fuel rail to soak up fuel leaks. Connect a fuel pressure gauge to the fuel pressure port and place the free end of the pressure gauges bleed hose into a gasoline container. Open the valve on the pressure gauge to relieve the pressure in the fuel system. Disconnect the fuel pressure gauge from the fuel pressure port.

3

Disconnect the outlet resonator of the air cleaner with a socket wrench. Detach the fuel lines from the fuel rail and unplug the electrical connectors for the fuel injectors. Disconnect the mounting bolts for the fuel rail and remove the fuel rail from the cylinder heads.

4

Release the retainer clip on the fuel injectors and remove the fuel injectors from the fuel rail. Remove the O-rings from the fuel injector and discard them.

5

Mount the new O-rings to the fuel injectors and attach the fuel injector clips. Install the fuel injectors into their corresponding sockets on the fuel rail so the electrical connectors face upward.

6

Align the fuel injectors with their respective cylinder head ports and install the fuel rail to the cylinder heads. Tighten the retainers for the fuel rail to 89 inch-pounds with a torque wrench.

7

Attach the electrical connectors to the fuel injectors. Connect the fuel lines to the fuel rail and connect the vacuum hose to the fuel pressure regulator. Install the outlet resonator for the air cleaner with a socket wrench.

8

Connect the cable to the negative battery terminal. Turn the ignition on for two seconds to pressurize the fuel system. Turn the ignition off and check for fuel leaks.

The Chrysler Concorde was a full-size sedan that Chrysler produced from 1993 to 2004. It was available with a 2.7-liter or a 3.5-liter engine, both with multi-point fuel injection. This design uses an electronically-controlled fuel injector to send fuel to each cylinder at the correct point in the cylinders combustion cycle. The procedure for installing a fuel injector is similar for both of the Concordes engines.

Instructions

1

Disconnect the fuel pump relay from the power distribution center in the engine compartment. Start the engine and allow it to stall. Continue to crank the engine until it no longer starts. Turn the ignition off, and replace the fuel pump relay.

2

Remove the cable from the negative battery terminal with a socket wrench to prevent the battery from producing sparks. Disconnect the plenum for the intake manifold, and cover the opening to the intake manifold with a clean shop cloth. Put a shop cloth under the quick-connect fittings on the fuel line, and squeeze the quick-connect fittings together. Detach the fuel line from the fuel rail.

3

Disconnect the electrical connectors from the fuel injectors. Remove the mounting bolts for the fuel rail with a socket wrench, and remove the fuel rail from the engine. Release the retainer clips on the fuel injectors, and detach the fuel injectors from the fuel rail.

4

Coat the O-rings on the new fuel injectors with engine oil, and install the fuel injectors to the fuel rail. Secure the fuel injectors with the retaining clips. Press the fuel rail into place on the cylinder head, ensuring that the fuel rail is fully seated.

5

Tighten the mounting bolts for the fuel rail to 100 inch-pounds with a torque wrench if you have a 2.7-liter engine. Tighten the mounting bolts to 21 foot-pounds if you have a 3.5-liter engine.

6

Remove the shop cloth from the opening of the intake manifold, and connect the plenum for the intake manifold with a socket wrench. Coat the quick-connect fittings on the fuel line with engine oil and connect the fuel line to the fuel rail. Attach the cable to the negative battery terminal.

The Volkswagen, or VW, Golf is a small family car that has been in production since 1974. The 1997 model belongs to the third generation of this series, which VW manufactured from 1991 to 1999. The fuel system in a 1997 VW Golf uses a small transfer pump, or sending unit, in the fuel tank to move the fuel out of the tank. The procedure for removing the fuel sending unit is generally the same for most VW cars made from 1993 to 1999.

Instructions

1

Raise the vehicle with a floor jack, and support it safely on jack stands.

2

Remove the fuel pump fuse from the fuse box under the dashboard, using the list on the fuse box as a guide. Start the engine, and allow it to idle until it stalls from fuel starvation.

3

Turn the ignition off, and disconnect the batterys negative cable with a socket wrench. Wrap a clean shop rag around a connection on the fuel line to soak up spilled fuel. Loosen the connection with a socket wrench to relieve the pressure in the fuel system. Tighten the fuel connection, and replace the fuse for the fuel pump.

4

Remove the rear seat from the vehicle, and disconnect the access cover under the seat with a socket wrench. Detach the electrical connector and fuel lines from the fuel sending unit.

5

Turn the retaining ring for the fuel sending unit counterclockwise with a socket wrench, and remove it from the fuel sending unit. Pull the fuel sending unit from the fuel tank, and empty the fuel in the sending unit into a container approved for gasoline. Discard the gaskets for the fuel sending unit.

6

Mount new gaskets to the new fuel sending unit, and install the sending unit in the fuel tank. Fasten the retaining ring to the sending unit with a socket wrench. Connect the fuel lines and electrical wiring to the fuel sending unit. Fasten the access cover for the fuel sending unit, and replace the rear seat.

7

Connect the batterys negative cable with a socket wrench, and lower the vehicle.

The Nissan 300ZX is a sports car manufactured by Nissan from 1984 to 1996 in the United States. The 1984 Nissan 300ZX has a 6-cylinder 3.0-liter engine, and some models have turbocharged engines. All versions of this vehicle use fuel injection, which requires a highly-pressurized fuel system. The fuel pump in the 1984 Nissan 300ZX is within the fuel tank, so you must remove it to install the fuel pump.

Instructions

1

Start the engine and disconnect the fuel pump relay in the fuse box. Wait for the engine to stall, and attempt to start the engine three more times to ensure you have completely relieved the pressure in the fuel system. Turn the ignition switch off.

2

Disconnect the electrical connectors for the fuel gauge and fuel pump in the trunk. Place a hose into the fuel tanks filler tube, and siphon as much fuel as possible into a gasoline container.

3

Detach the ring for the fuel filler neck on the fuel tank with a socket wrench, and remove the right rear wheel. Disconnect the protectors for the fuel filler tube protectors and the fuel lines to the fuel tank.

4

Support the fuel tank with jack stands, and loosen the bolts for the retaining straps on the fuel tank. Disconnect the fuel tank and remove it from the vehicle.

5

Turn the retaining ring for the fuel pump counterclockwise with a hammer and brass drift. Remove the retaining ring, and lift the fuel pump out of the fuel tank.

6

Install the new fuel pump by performing steps two through five in reverse order. Replace the relay connector in the fuse box, and fill the fuel tank. Start the engine, and check for fuel leaks.

The Mitsubishi 3000GT is a performance car and is also called the GTO. From 1991 through 1996, the 3000GT and the Dodge Stealth were manufactured identically. The fuel pump in a performance vehicle is directly involved in how well the engine runs. A clogged fuel pump will cause the engine to misfire, gas mileage to rise and performance to drop. Changing the fuel pump as soon as it begins to break down will prevent future problems.

Instructions

1

Park the Mitsubishi 3000GT on a flat, level surface, and set the parking brake. Open the hood, and disconnect the negative battery cable.

2

Place the jack under the front of the car at the center of the frame. Lift the vehicle, and place jack stands under the front axles.

3

Remove the cap to the fuel tank to release pressure on the fuel lines.

4

Follow the fuel line coming out of the fuel tank to locate the fuel pump. Unplug the fuel pumps wiring harness. Place a drip pan under the fuel pump. Loosen the hose clamps with a slotted screwdriver, and disconnect the fuel lines. Point the fuel lines at the drip pan when they come loose to catch any spilled fuel, then dab the ends of the lines with a rag to clean up the remaining fuel.

5

Remove the mounting bolts with a socket wrench. Remove the fuel pump.

6

Attach the new fuel pump, and tighten the mounting bolts with a socket wrench. Attach the fuel lines to the fuel pump and tighten the hose clamps with a slotted screwdriver. Plug in the fuel pumps wiring harness.

7

Remove the jack stands, and lower the car. Pump the gas pedal a few times to get fuel into the fuel lines.

The Chevrolet S-10 is a compact pickup truck that General Motors manufactured from 1982 to 2004 in the United States. It had a 6-cylinder 4.3-liter engine with sequential fuel injection, which requires a high-pressure electric fuel pump. The fuel pump in a 1998 Chevrolet S-10 is attached to the fuel tank. This requires you to remove the fuel tank before you can install the fuel pump.

Instructions

1

Disconnect the cable from the batterys negative terminal with a socket wrench to prevent starting the engine accidentally. Open the fuel tanks filler cap to relieve the pressure in the fuel tank.

2

Siphon the fuel through the filler tube with a hose and drain the fuel into a gasoline container. Raise the rear of the truck with a jack and support it on jack stands. Remove the plastic tank from the fuel tank with a socket wrench. Release the clamp for the fuel tanks filler hose and disconnect the filler hose.

3

Disconnect the electrical wiring and fuel lines from the fuel tank. Support the fuel tank with a floor jack and remove the fuel tank straps with a socket wrench. Lower the fuel tank slightly with the floor jack. Detach the electrical connections and fuel lines from the fuel sending unit. Lower the fuel tank completely with the floor jack and move it to your work area.

4

Turn the locking ring for the fuel sending unit counterclockwise with tool No. J-24187. Remove the locking ring from the fuel sending unit and lift the fuel sending unit out of the fuel tank. Discard the O-ring for the fuel sender unit. Pull the fuel pump into the mounting tube as you pull it away from the bottom support. Pull the fuel pump out of the rubber connector once it clears the bottom support.

5

Install the new fuel pump and O-ring by performing steps one through four in reverse order. Start the engine and check for fuel leaks.

The 1ZZ-FE is a four-cylinder 1.8-liter engine that is most common on Toyota vehicles made from 1999 to 2005. This engine uses sequential fuel injection, which requires the fuel injectors to deliver fuel to the engine under high pressure. The fuel injectors for a 1ZZ-FE engine are on top of the engine, and are accessible from the engine compartment. The replacement of the fuel injectors in this engine requires the removal of additional engine components.

Instructions

1

Remove the fuel pump fuse from the fuse box under the dashboard. Start the engine and allow the engine to stall. Crank the engine to ensure the fuel lines are empty and replace the fuel pump fuse. Disconnect the cable from the negative battery terminal to prevent the battery from generating sparks during the fuel injector replacement.

2

Disconnect the cover for the No. 2 cylinder head with a socket wrench. Detach the vacuum hose and fuel tube from the fuel pipe. Disconnect the electrical connectors from the fuel injectors.

3

Disconnect the fuel pipe from the fuel injectors and detach the fuel injectors from the engine. Remove the spacers from the cylinder head and pull the fuel injectors away from the fuel pipe. Discard the O-ring and grommet for the fuel injectors.

4

Coat the new O-rings and grommets with light machine oil before installing them onto the new fuel injectors. Coat the mounting surfaces on the fuel pipe with light machine oil. Install the new fuel injectors into the fuel pipe by twisting them into place so that the electrical connectors face away from the fuel pipe. Coat the injector bores in the cylinder head with light machine oil.

5

Install the spacers and connect the fuel pipe to the cylinder heads. Tighten the mounting bolts for the fuel pipe to 14 foot-pounds with a torque wrench. Attach the fuel line and the PCV hose to the fuel pipe. Connect the cover for the No. 2 cylinder head and tighten its mounting bolts to 7 foot-pounds. Connect the cable for the negative battery terminal with a socket wrench.