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Category: Fuel System

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September 26, 2026 BY
IN Fuel System

Fuel Pump Replacement

The fuel pump supplies pressurized gasoline to each of the fuel injectors in a car’s engine. The fuel pump is powered by a compact electric motor and is located in the vehicle’s gas tank. The pressure and output of the pump are controlled by a regulator. Filtration of the fuel occurs either in the fuel tank using a pickup screen or externally with a replaceable filter mounted in the fuel supply line. When to consider replacing the fuel pump? A high quality, OEM fuel pump can last indefinitely. However, as with any electro-mechanical component, a fuel pump will eventually degrade and fail. If it fails to produce adequate pressure or completely quits operating, it will need to be replaced. This failed condition can sometimes be preceded or accompanied by one or more of the following symptoms: Car won’t start or unexpectedly stalls and won’t re-start. A failed fuel pump may prevent a car from starting or stall it. Check engine light is on. Sometimes a fuel pump will fail slowly, and that means the fuel pressure and volume slowly degrades. The lack of fuel may result in the engine operating without enough fuel relative to the amount of air, causing the check engine light to appear. Whirring noise from fuel tank. As a fuel pump fails, you may notice a whirring or humming noise coming from the fuel tank area, toward the rear of the car. If the noise is from the fuel pump, failure of the pump is often imminent and you should replace the fuel pump at your earliest convenience. How do mechanics replace the fuel pump? The fuel pump is tested to be sure it isn’t functioning. Should the fuel pump be faulty, it is removed from the tank through an access panel above the tank in the passenger compartment. When no access panel exists, fuel is first drained from the tank and then the fuel tank must be lowered from the vehicle to gain access to the pump. In all cases, fuel pump supply and return hoses, as well as EVAP system hoses, and electrical connections to the pump must be removed. Once the pump is out, any reusable brackets and pick up screens are attached to the new pump, then the new pump is installed. If the fuel system uses an in-line external filter, a filter is often replaced. All hoses and electrical connections are re-established. Fuel is added to the tank and the engine is run to test for leaks. Is it safe to drive with a fuel pump problem? Usually, it’s still safe to drive, but the pump may lead to an overheated engine and catalytic converter. Complete fuel pump failure can leave you stranded out on the road, but many times a car won’t start before initially driving. However, if the fuel pump problem involves leaks of gasoline or vapors, it is unsafe to continue driving, and should immediately be checked by a qualified mechanic. When replacing the fuel pump keep in mind: Prior to replacing, the mechanic will power the fuel pump directly to confirm that the issue is a failed pump versus a faulty power supply to the pump. Unless the fuel filter was replaced recently, whenever the fuel pump is replaced a new fuel filter should be installed. When failing earlier than expected, the power supply should be verified because a voltage drop in the fuel pump circuit can lead to overheating. Should the fuel tank be lowered during the repair, the fuel tank straps and fasteners should be checked for excessive corrosion and replaced as needed. The fuel in the gas tank cools and lubricates the fuel pump. After installation of a new fuel pump, it’s wise to keep the gas tank at least a quarter full to maximize the life of a new fuel pump.

 

 

 

 

September 26, 2026 BY
IN Fuel System

Gas Cap Replacement

The purpose of a Gas Cap is twofold: one, it helps prevent dust and other particles from getting into the gas tank, and two, it helps prevent fuel emissions from entering the atmosphere. If your gas cap is faulty, the Check Engine light may come on. Additionally, your vehicle may fail a smog test if the gas cap is gone or not functioning properly.

 

 

Inspect the gas cap. | Pressure-test the gas cap. | Install new gas cap if faulty.

 

 

September 26, 2026 BY
IN Fuel System

Injector Control Pressure

In a fuel injection system, it’s important that the computer has information concerning the amount of fuel pressure in the rail at all times. This information is necessary for the computer to determine the actual injector timing, the width of each pulse, and the pressure required during operation. In some diesel engines (notably many Ford engines), this job is done by the injector control pressure sensor, or ICP. The sensor works on the basis of capacitance, and feeds an analog voltage signal to the vehicle’s computer that tells it how much pressure is in the rail. Like all other sensors, the injector control pressure sensor is subject to wear and tear and eventual failure through normal use. If it fails, the computer will be unable to determine the pressure in the rail, which will adversely affect the operation of the engine.

 

The injector control pressure sensor is not inspected during normal maintenance. | The sensor can fail due to wiring problems, sensor deterioration, degradation, and other causes. | The sensor is part of the fuel system. Do not attempt to work on this yourself.

 

The vehicle is lifted and supported on jack stands | The defective injector control pressure sensor is removed | The new injector control pressure sensor is installed | The new sensor is checked for proper operation and jack stands removed | The engine is run and vehicle is road tested for proper operation

 

Without an operational ICP, your vehicle’s computer will be unable to operate the fuel injection system correctly. This can result in a number of problems, ranging from lean or rich operation to the Check Engine light turning on. Have a faulty sensor inspected immediately.

 

It is absolutely essential for your vehicle’s computer to be able to determine the pressure in the rail at all times. If the ICP fails or is failing, expect erroneous engine operation, rough idling, and the Check Engine light to turn on. Have this issue diagnosed immediately. Remember – fuel system work is never something that should be undertaken on your own. Always leave it to our expert mechanics with the proper work area, experience and safety equipment.

September 26, 2026 BY
IN Fuel System

Oxygen Sensor Replacement

With each new model year, manufacturers are adding more oxygen sensors to better manage engine operation. Some high performance engines have an oxygen sensor for each cylinder as well as one for the rear of each catalytic convertor. The sensors are located either underneath the hood or underneath the car. The oxygen sensors are connected (screwed) to the exhaust pipe, either in front or back of the catalytic converter. The front (upstream) sensors measure the amount of oxygen in the exhaust system. The purpose of the front oxygen sensor(s) is to measure how rich or lean the gases are as the gases exit the combustion chamber. Depending upon whether the exhaust gas is lean (high in oxygen content) or rich (low in oxygen content), the amount of fuel entering the engine is adjusted by the engine management computer to try and maintain an ideal mixture that produces the lowest emissions output from the catalytic convertor. Rear (downstream) sensors are located behind the catalytic converter. The purpose of the rear oxygen sensor(s) is to monitor the oxygen content of the exhaust gases leaving the catalytic convertor. If one or more of the oxygen sensors are faulty, your car may not pass the emissions test. If you drive your car with a faulty oxygen sensor, you may get poor gas mileage and it can damage the catalytic converter. When replacing the oxygen sensor remember: Many oxygen sensors are damaged by leaking oil or coolant. If that is the case, the cause of that leak needs to be identified and repaired, or else the replacement oxygen sensor will be damaged as well. New vehicles require specific oxygen sensors, and not the universal sensors that were common prior to 1996

 

 

Scan the computer in the car for codes. | Inspect for vacuum leaks and holes in the exhaust system. | Remove and replace the oxygen sensor if it is bad. | Check electrical connections. | Check for proper operation of oxygen sensors. | Clear diagnostic codes. | Test drive car.

 

Keep up with the tune-ups. If check engine light is on, don’t drive the car too long without getting it inspected. If check engine light is flashing, pull over and get the car towed to avoid costly repairs. Ask the mechanic to inspect the vacuum hoses and leaks in the exhaust system. If the vacuum hose or exhaust system is leaking, it will display an oxygen sensor fault code. Replacing an oxygen sensor may not fix the problem.

 

September 26, 2026 BY
IN Fuel System

Fuel Filler Neck Replacement

The fuel filler neck is a part that connects the gas cap and the fuel tank. It may be a metal hose that is soldered to the fuel tank, or a rubber hose that uses hose clamps to hold the neck to the gas tank. When the neck is metal, it is made of lightweight aluminum, steel or chrome plating. Modern necks are powder-coated to increase their lifespan. While they are designed to be long-lasting, corrosive chemicals can cause them to wear and rust over time. They will develop holes and cracks that allow the fuel to leak out. Not only does this create a fire hazard, but it allows dust and debris to seep inside and reduce the performance of your vehicle. Accidents or collisions can also damage the fuel filler neck. While it can be temporarily patched with an adhesive, replacement is often the better long-term fix.

 

A leaking fuel filler neck is a fire hazard. | Fuel vapors are dangerous when they leak | The fuel filler neck should have a 45-degree angle tilt | The neck must have the correct diameter to fit the opening of the fuel tank

 

The vehicle is raised and supported on jack stands and wheel is removed | The inner fender is removed and defective filler neck is removed | The new fuel filler neck is installed and the inner fender installed | The vehicle is removed from the jack stands | The vehicle is road tested for proper operation

 

If you smell fuel vapors or suspect your fuel filler neck is leaking, have our expert mechanics look at it. They will inspect it for cracks, leaks, and other types of damage. They may also check the seal around the neck to make sure it is working properly. A replacement fuel filler neck will take care of the problem and provide a protective seal.

 

Because a leaking fuel filler neck can be a fire hazard, you should have it checked and repaired promptly. If you notice a change in mileage on your vehicle or a puddle of fuel when you fill up your gas tank, have a mechanic inspect your fuel system, including the fuel filler neck. Poor fuel economy is costly and adds up over time.

September 26, 2026 BY
IN Fuel System

Fuel Filter Replacement

The fuel filter is made of cellulose or synthetic-based filter media that traps extremely tiny contaminants, such as rust particles and dirt, present in the fuel as it flows from the fuel tank to the fuel injectors. The filter media is sealed within a cylindrical shaped housing that looks like a tiny soda can. You will most often find the fuel filter plumbed into the high-pressure fuel supply line beneath the car, right next to a sturdy frame rail. Some fuel filters, particularly on diesel-powered vehicles, have water traps as well. Some newer cars do not have serviceable fuel filters as the filter is built into the fuel pump located in the fuel tank. When to consider replacing the fuel filter: Scheduled maintenance. The most common reason to change the fuel filter — your vehicle’s maintenance schedule may specify a filter change interval. Fuel contamination. If any foreign fluids, bad fuel, or water enters into the fuel system mistakenly, the fuel filter should be replaced. Fuel system repairs. If the fuel pump has been replaced, work has been performed on or in the gas tank, or the fuel injectors have been cleaned or replaced, always install a new fuel filter. Major engine repairs, or engine replacement, also require a new filter. Leaks. There should be zero leakage of fuel, whether liquid or vapor, in the fuel system. Leaks at the fuel filter connections might necessitate not only a new fuel filter but also new O-rings in the push-on connections to the fuel filter. Warning light indication. Diesel powered vehicles may be equipped with a water-sensor warning light circuit to signal the driver if excessive water has accumulated in the fuel filter. The water will have to be drained and the filter possibly serviced or replaced. How do mechanics replace the fuel filter? A clogged fuel filter that is integral to the fuel pump must be removed with the fuel pump from the fuel tank to perform service. For all other vehicles, the procedure begins with raising the vehicle and supporting it with steel jack stands. The fuel system is depressurized so the filter can be removed from the high-pressure fuel line without gas spraying out. The in-and-out connectors to the filter are removed and the filter is removed from the fuel line. The new filter is installed using a small amount of oil on the O-rings to ease re-installation of the quick connect fittings. The fuel system is then checked for leaks while the engine is running. Is it safe to drive with a fuel filter problem? Yes, so long as the fuel filter is not leaking. If there is a leak, have it repaired before driving the car. If clogging is suspected and potentially causing engine operating problems, have the cause investigated and resolved at your earliest convenience. In extreme cases, a very old filter that may be plugged could disintegrate, allowing what were trapped contaminants to reach the fuel injectors and causing additional problems. When replacing the fuel filter keep in mind: A plugged fuel filter can be ruled out using pressure and volume tests on the fuel system. Given enough elapsed mileage though, all fuel filter replacements should be done as basic maintenance, and so complicated tests are not necessary if the filter is already known to be old. Consult the vehicle maintenance schedule to determine when to replace the fuel filter. If you have bought contaminated gas, once all fuel system repairs are made, always install a new filter. Gasoline is perishable and will eventually degrade into compounds that will damage the fuel system. Generally, if a car has sat unused with gas in the tank for more than 3 to 6 months, the gas should be drained and the fuel filter replaced.

 

 

 

 

September 26, 2026 BY
IN Fuel System

Fuel Gauge Sender Replacement

The fuel gauge sender is a fairly simple component that is located in your car’s fuel tank. It consists of a float that is connected to a metal rod. The end of this thin rod is mounted to a resistor, which measures electrical flow. When there is more resistance, less current flows. A slider connected to the fuel gauge slides on the metal strip, and delivers current to the resistor from the gauge. If the slider is close the grounded side, there is less resistance, and if it’s at the end of the strip, there is more resistance. The fuel gauge on your dash interprets the resistance and indicates the fuel level with a needle on your cluster. If the fuel gauge sender isn’t working, you will get an inaccurate reading on your fuel gauge.

 

Fuel gauge inaccuracy may not be due to a faulty fuel gauge sender – something as simple as the shape of the tank can affect the position of the float and throw the reading off.

 

The battery is disconnected and the fuel tank is removed | The defective fuel gauge sender is removed | The new fuel sender is installed and adjusted | The fuel tank is reinstalled and the battery reconnected | The repair is verified and the fuel gauge sender tested for proper operation

 

Variations in gas gauge readings are common, but if you notice a significant difference in what the gauge tells you, and what you know is in your car gas tank, have one of our expert mechanics diagnose the problem with the fuel gauge sender and replace it if necessary.

 

The fuel gauge is a convenience item; if you run out of fuel, you may be stranded. If your fuel gauge sender has failed or is working intermittently, have it replaced when you can. Make sure to fuel up regularly to avoid running out of fuel.

September 26, 2026 BY
IN Fuel System

Fuel Injector O Rings Replacement

Fuel injector O rings are rubber gaskets around the end of the fuel injectors that hold the injectors up tight to the rest of the cylinders of your engine, and prevent fuel from leaking. If they’re not properly mounted, or if they’ve begun to deteriorate, you will lose fuel. They work like any other gasket – they will wear and crack as they age, and at some point will require replacement.

 

Fuel injector O rings are not inspected as part of your routine maintenance, but if your car has accumulated tens of thousands of miles, it is a good idea to have your mechanic check them out. | If your car is losing fuel, the rings may be at fault. | Don’t assume that the problem is with the O rings – your injectors could be clogged.

 

The vehicles hood is opened and battery disconnected | The defective fuel injector O-rings are removed | The new injector O-rings are installed | The battery is reconnected and engine started | The repair is verified for no fuel leaks and tested for proper operation

 

Fuel injector O-rings are not part of a maintenance inspection or service and are only addressed when there is a fuel injection problem or a fuel leak at the engine. If you suspect your fuel injector O-rings are leaking, have one of our expert mechanics inspect and replace them as necessary.

 

A fuel leak at the engine can cause a fire if the fuel ignites. Have leaking fuel injector O-rings replaced as soon as possible.

September 26, 2026 BY
IN Fuel System

Fuel Injector Replacement

A fuel injector is a fuel metering device that sprays atomized droplets of fuel in a specific pattern into the engine’s intake manifold or directly into the combustion chamber. The injector has a solenoid and valve within and the operation, or pulsing, of the solenoid is controlled by the powertrain control module (PCM). The PCM controls the solenoid’s “on” time in order to keep the air-fuel ratio optimized while the engine load and operating conditions constantly change. Fuel injectors are usually connected to a fuel rail located on the top of the engine and the fuel rail, in turn, is supplied with fuel under pressure from the fuel pump located in the fuel tank. When to consider replacing a fuel injector: Rough idle, loss of power, or misfiring. Poor engine operation has many causes but faults in the fuel injection system, including the fuel injectors, are high on the list of possibilities. Odor of raw gas or visible leaks. Fuel injectors should not leak fuel into the intake manifold when the car is off. If you notice any fuel odor around your car, the possibility of a leaking fuel injector should be considered. There should be no external leak from a fuel injector. If an externally-leaking injector is suspected, do not start your car due to the fire hazard. Check engine light. Some fuel injection failures, for example, a faulty solenoid, may cause a trouble code to be set in the PCM and that will cause the check engine light to illuminate. The codes are read and the fuel injector is tested directly, as needed. Major engine repairs, engine replacement, or lengthy storage. All fuel injectors will have deposits given enough mileage. These deposits can cause an imbalance in the performance of the injectors from cylinder to cylinder. When an engine is already disassembled, or if you are installing a new engine, that is a perfect time to service the injectors as a set. All injectors have tiny internal filter baskets. A professional injector service facility will clean each injector ultrasonically and replace these filters for a relatively low cost. How do mechanics replace a fuel injector? Injectors can be serviced once removed from the car or replaced outright with new injectors. If the injectors are serviced, specialized cleaning and test equipment are required. The choice to repair versus replace will depend on exactly what is wrong with the injector as well as customer preference. Either option requires removing the injector from the car and the following procedure is typical: Once the engine is cold, the pressure within the fuel rail is relieved by briefly running the engine with the fuel pump fuse out. The upper plenum on the intake manifold is removed along with any cables, hoses, or wiring that restricts access. The supply and return lines are removed from the fuel rail. The electrical connectors to each fuel injector are unlocked and removed. The fuel rail is then unbolted and removed from the intake manifold. The injector(s) requiring replacement are removed from the fuel rail, taking care to not allow any debris to enter the exposed openings. An O-ring seal usually holds the injector very firmly in a finely polished bore in the fuel rail. Using a new O-ring, the serviced or replaced injector is re-inserted into the fuel rail — using engine oil on the O-ring to prevent damaging it. O-rings in this application fit very tight to prevent fuel leaks. The fuel rail is re-installed and the supply and return lines are re-connected. The plenum is re-installed along with all cables, hoses, or wiring. Finally, the engine is run, there is a careful check for leaks, and the vehicle is road tested. Is it safe to drive with a fuel injector problem? Yes, so long as there is no external leak of fuel from a broken or malfunctioning injector, it is safe to drive the car. However, if the injector is known to be malfunctioning, it can cause engine misfires, excessive emissions or, in the case of a badly leaking injector, can overload and overheat the catalytic converter. Additionally, fuel efficiency will always be diminished if the fuel injectors are not working properly. When replacing a fuel injector keep in mind: Using high quality (Tier One) gasoline may reduce deposits on fuel injectors and prolong their life. If an injector problem develops that requires removal of one injector, the best practice is to remove and service all of the injectors at the same time. That service might involve replacement of the electrically failed injector along with off-the-car cleaning of the remaining injectors. Serving all injectors at once ensures the injector set will be balanced, in terms of flow rates, and in turn promote smooth operation of the engine. Do not use fuel system cleaning compounds, or procedures, unless such materials are specified by the manufacturer of your car. On the car cleaning of fuel injectors is not as effective as off-the-car cleaning because injectors have tiny internal filter baskets that should be replaced as part of the process of servicing a fuel injector.

 

 

 

 

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