Replacement of the fuel pump generally takes about 2 to 4 hours, depending on the model of the car, where the pump is situated, and how much extra steps may be required. In most vehicles, the fuel pump is inside the fuel tank, so it requires partial or full removal of the tank, which complicates the process and takes a little more time. This can be closer to 2 hours for SUVs and trucks, whose tank placements or access panels are more accessible. In compact cars, which offer extremely limited access to the tank, replacement times extend closer to 4 hours.
Labor involved is one of the major time factors, as mechanics charge hourly rates that generally range between $75 and $150. For a job that could span 3 hours, labor costs alone can total $225 to $450, not including the fuel pump itself, which ranges in price from $50 to $300 based on quality and compatibility. The fact that some of the OEM pumps are designed for specific makes and models accounts for higher costs due to their durability and assurance of specifications met. The more expensive pumps not only add up in the initial cost, but they usually tend to have longer life spans, avoiding frequent replacements.
Other necessary procedures include relieving fuel pressure, which increases replacement time even more. Fuel-injected engines operate under high pressure, normally between 30 and 60 psi; this has to be worked around carefully to avoid spray hazards. Mechanics will use special tools to disconnect the fuel lines in a safe manner, releasing the pressure without spills-a procedure that takes some extra 20 to 30 minutes in the replacement process. This is a necessary step for safety; fuel vapors can be highly flammable.
Corrosion near the fuel tank or connectors can further complicate the replacement. High-mileage cars-or those that often face exposure to moisture or road salt-may have rusted components; for this, extra time is required to clean up or replace these parts. Mechanics sometimes run into seized bolts or seized connectors, adding up to an hour to the job if it requires specialized tools or rust treatments.
Moreover, since a badly installed or out-of-align pump could lead to leakage or fluctuating fuel pressure which eventually affects vehicle performance, proper installation and testing will be required after replacement. Many mechanics after installation conduct a fuel pressure test to ensure that the new pump provides the appropriate psi range needed for smooth operation in a vehicle. Besides the use of appropriate tools, the proper knowledge of such steps would keep well-timed managing possible for do-it-yourself enthusiasts. In any case, for precision and safety, professional service is usually recommended. For details on selecting and installing a good fuel pump, refer to Fuel Pump.