Having a broken fuel pump can cause a number of problems, including increased fuel consumption and environmental contamination from spilled oil and gas. Changing the fuel pump on a Suzuki Samurai is a relatively easy process.
Tools Used: Socket wrench with extensions, Flathead screwdriver, 12mm socket, New fuel pump with gasket, Pliers, Engine oil, Rags
Install a Fuel Pump
Disconnect the battery. Open the fuel cap to release pressure, then replace the cap.
Loosen the hose clamps on the fuel lines that connect to the pump. Turn the screw counterclockwise two or three full turns for screw-type hose clamps. Squeeze with pliers for squeeze-type hose clamps. Disconnect the fuel lines. Dab the ends of the fuel lines with a rag to keep fuel from dripping.
Remove the two nuts that hold the pump to the cylinder head. Put the nuts in a safe place. Remove the fuel pump. Remove the old gasket. If the old gasket is difficult to remove, use the flathead screwdriver to pry it from the cylinder head. Take care when removing the gasket so as not to damage the cylinder head with the screwdriver.
Dab a little engine oil on the end of the pump push rod and the new fuel pump mechanism.
Put the new gasket on the studs. Hold the fuel pump on the studs and tighten the nuts securely.
Reconnect the three fuel lines and tighten the clamps securely.
Connect the battery and start the engine. Check for any oil or fuel leaks from around the fuel pump.
Tips & Warnings
Old fuel pumps should be cleaned of fuel and oil before disposal. Allow the fuel pump to dry out completely before throwing it away.
Not releasing pressure by opening the gas cap can cause fuel to spray everywhere when the fuel lines are removed from the pump.
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