Question about 2004 Ducati Monster 620 Capirossi

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How to remove fuel pump?

I'm putting on a new gas tank and need help on how to remove the fuel pump and insert it in the new tank???

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  • Ducati Master
  • 1,369 Answers

If you have a Front and/or Rear stand, put the bike up on it. Make sure you are working in a well-ventilated place that is not sensitive to fuel vapors and spills. Although fuel spill should be very minimal (around 2 ounces), there will be a strong smell of fuel.

--- Siphon out of as much gas from the Fuel Tank as you can, collect it in a gasoline container... place in safe place. (You do not need siphon fuel out if you are not removing the fuel pump, which is located inside the tank. You only need to make sure that you have no more than 1/2 tank of fuel in there, and keep the tank propped-up - you should have little or no problems with fuel spilling then)

--- Remove the 3 allen bolts under the seat section on each side of the bike.
At the very tip of the tail fairing, you will need to gently "pop" off the tab (underneath) that connects it to the sub frame. There is no bolt to unscrew, just a tab you need to pop-away with slow, progressive pressure until come off. (this is for monoposto, may be slightly different for biposto)

--- The TAIL FAIRING, the SEAT and the FUEL TANK are all connected into one whole assembly. You will first need to separate the fuel tank. To do that, lift UP on the whole assembly and prop it up.
After you have propped-up the TAIL-SEAT-TANK assembly, remove the 17mm Bolt underneath the seat, in order to separate the TAIL-SEAT from the TANK.
Put the TAIL-SEAT Assembly in a safe place where it will not be damaged or scratched.

--- Now you can work exclusively on the Tank. The first thing you need to do is get an old towel or good size rag to place underneath. There will be a minimal amount of fuel spill, so put that on to protect your engine from getting fuel spilled on it.

--- There are 3 couplings underneath the tank that you need to remove. Two of them are fuel lines, the other one is a power line.
Disconnecting the fuel lines are a bit tricky. You need to just squeeze them and they will come off. If you have large fingers, call your S/O and make her do it ... or for lonely guys, you might have some luck with needle-nose pliers.

--- As you handle the tank from this point forward, keep the tank propped-up, to avoid any further spilling.

--- Next, disconnect the 2 breather hoses in front of the tank. You will need to squeeze the connector with pliersso that it comes loose. Do not use hard pressure, only slow progressive pressure. Nothing will spill out of these hoses.
Once you have disconnected all lines and hoses from the Tank, you are ready to remove the tank. The front of the tank is connected through two guide pins - all you need to do is just slide the tank towards the back end of the bike and it will come off. Have a ready area to put it down where it will not get scratched... make sure that the Fuel Pump is at the top end, so as to avoid any spilling.

To remove the Fuel Pump:

--- remove the 3 bolts that attach the Pump to the tank. Once removed, slowly pry-off the pump assembly away from the Tank with the help of progressive pressure on a flat head screwdriver. Try to do it evenly a little bit at a time, on each of the 3 sides... that makes it easier to remove.
--- You will need to slowly move the fuel pump assembly around to get the whole thing to come off the opening in the tank. There is an O-Ring there that is most likely damaged due to dis-assembly, so you will need to replace that. This is very important ... if not, it will most likely lead to a huge Fuel Spill (guess how I know that).
When putting the fuel pump back,, with NEW O-Ring, apply a liberal amount of grease, vaseline or some lubricant... if you do not apply enough lubricant, you will run a very high risk of: (1) HAVING A VERY DIFFICULT TIME REINSTALLING THE FUEL PUMP; (2) STRIPPING THE 3 CONNECTION SCREWS due to uneven flange and/or (3) DAMAGING THE O-RING.
When reinstalling the fuel pump assembly, make sure that you try to pop it in with progressive hand-force, and as evenly as possibly through out the 3 connection points. If you put enough lube, things should slide in with relatively little effort, and all you will need to do is just bolt the 3 screws back.

So that's it... to reinstall, just do everything Backwards!

Hope this helps

Posted on Mar 07, 2016

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Posted on Jan 02, 2017

agent91
  • 2100 Answers

SOURCE: My 2005 Ducati Multistrada is hard to start in cold weather

That is not the fuel pump you hear, the pump is vacuum and the noise you hear is the ignition coming to life. Don't use any additives in your fuel, bad news, and just use the choke only, twisting the throttle does nothing till the engine starts. The choke is a slow speed jet. There is no way to check the air filter without pulling the seat and lifting the tank. But I have never found mine dirty, and I live on a dirt road. I call it the multistrada. 02 ,S4. Are you burning high test? 92 octane? How about keeping it warm or under cover? I think the fuel problem might be the dampness, humidity, etc, How about them spark plugs? Check them lately? I switched to autolites, they work a lot better than the champions. Hope this helps.

Posted on Apr 18, 2010

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To start, the fuel pump assembly is mounted in the gas tank. Jack up the truck and support with jackstands. From underneath you will need to disconnect the filler and overflow hoses from the tank, by removing the worm gear clamps holding the hoses to the metal filler tubes. Unbolt the two straps that are bolted to the underneath side of the body holding the gas tank to the underside of the truck, support the tank with jack, after the straps are undone, lower the gas tank some to get enough room to remove the fuel lines and the fuel pump/sending unit connector, also remove the small vacuum hose at the other end of the tank. Let the tank down, with a hammer and a screwdriver, turn the lock ring until it releases the pump assembly and remove. You may want to drain the gas from the gas tank, it always seems that the fuel pump goes out when you have alot of gas in the fuel tank, that will help when you go to put the fuel tank back into the truck. Reverse the procedure to install. Some Blazers have a plastic tank and some have a steel tank. You'll need to know which one when you go to buy the new one. They run about $250.00 at Auto Zone. I would also replace the fuel filter at this time also so you are starting out with everything fresh. Should take 2-4 hours to do the job. Have a few large gas cans to put the gas from the tank in.

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To gain access to the fuel pump, it is necessary to remove the fuel tank.
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  2. Remove any dirt that has accumulated around the fuel pump module attaching flange, to prevent it from entering the tank during service.
  3. Turn the fuel pump module locking ring counterclockwise using a locking ring removal tool or a brass drift and remove the locking ring.
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To install:
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  2. Insert the fuel pump module into the fuel tank, then secure it in place with the locking ring. Tighten the ring until secure.
  3. Install the tank in the vehicle.
  4. Install a minimum of 10 gallons of fuel and check for leaks.
  5. Install a pressure gauge on the throttle body valve and turn the ignition ON for 3 seconds. Turn the key OFF , then repeat the key cycle five to ten times until the pressure gauge shows at least 30 psi.
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Where is fuelpump on 2003 crown vic police intercepter


Dear cdkkks,

Replacing a fuel pump in modern cars requires some preliminary electrical, fuel test analysis work. I have noted some professionals indicating you need to run car until gas lines, tank is empty; more than likely, if your fuel pump is defective, you cannot start the car, car is unoperative; you will attempt to start car, starter will turn the engine over rapidly without starting, let's assume you are in this condition.

First we need to test the fuses and fuel pump relay, basically the electrical opportunities on your vehicle, the relay panel is on the fender well, driver side, lift the relay control assembly from the fuse center and press the tab on the end, push down and this will release relays from the cover. This relay control panel includes the PCM power relay (left side in original position) Fuel pump relay (Center) this is the relay you are concerned with and the Air Conditioning relay on (Right). If you have friends, or associates who have electrical equipment to test the fuel pump relay, utilize their help, some automotive shops will provide this service. Checking the relay circuit with a jumper wire, any scrap piece of wire, 16-18 gauge will do; as you are looking directly down at the relay opening, you will note an opening at the 6:00 and 12:00 clock positions, 6:00 is the positive, 12:00 is the neutral, volt meter set for volts will confirm. Open the gas cap from the fuel tank filler pipe, insert the jumper wire and carefully listen for a whirring sound. If there is no sound and you have confirm electrical pump fuses, fuel pump relay is working properly (Voltage is pressure, battery voltage and slightly less voltage at the relay circuit when ignition key is turned on) then we have couple more checks to perform before we replace fuel pump. Let's check the fuel rail pressure on your Ford Crown Vic, obtain a fuel compression gauge with a Ford Schrader valve adapter, check to verify that no fuel pressure exists. If "NO" fuel pressure exists, and we have confirmed the voltage integrity of relay/fuel pump circuit, then we are ready to remove fuel pump. Use a simple gas siphoning kits from your local auto parts outlets to safely remove all remaining gas from gas tank, use appropriate gas tanks to store fuel; safety is the key here, gas and gas fumes are extremely dangerous; use appropriate chemical/gas gloves when siphoning/handling gas.

(A) Park your Crown Vic, perferably in a garage, concrete floor and make sure there is enough room around the back of the vehicle for you to work and move tools around.

(B) Raise the back of your car using a floor jack and support it safely on wheel/jack stands; remember, the driver side rear wheel must be removed in order to remove the fuel tank filler pipe, place your wheel stand (supplement with 2 by material for proper height on frame,slightly forward of rear wheel); safety is the key issue here and I cannot overly emphasize this issue, heavy wheel stands should be supporting the right rear wheel and frame, slightly forward of rear wheel, driver side).

(C) Disconnect the fuel tank filler pipe and the fuel pump connector located above the cross member underneath the vehicle, you must remove the (3) screws on the topside (fuel tank fiiler pipe) and approximately (4) screws on the bottom side, and the (1) screw adapter plate where the fuel tank filler pipe is inserted into the gas tank, top of wheel opening, underneath the vehicle. After these connections are removed, push the fuel tank filler pipe further into the fuel tank, allowing you additional room to lower the filler pipe from it's current position, downward; once you have sufficient clearance, twist, turn left, slightly back and forth movements and carefully pull outward, removing the filler pipe from gas tank. Do not damage the rubber groment in gas tank as you remove the filler pipe. As a note, when you reinstall the filler pipe, insert small amount of vasoline on filler pipe end that is inserted into the gas tank to facilitate the installation process.

(D) Support the fuel tank with a jack and remove the nuts from the holding strap using a wrench or ratchet and socket. Move the strap away and slightly lower the fuel tank in order to disconnect the vapor tube from the tee connector on the right and the vapor line from the canister tube. Discard the fuel tank mounting studs and replace with new fuel tank mounting studs on the reinstallation process.

(E) Unplug the pressure transducer electrical connector located on the top rear corner of the fuel tank.

(F) Clean area around the mounting fuel pump mounting flange. Remove/disconnect the fuel lines attached to fuel pump mounting flange then remove the fuel pump mounting flange mounting bolts in a crisscross pattern.

(G) Lift the fuel pump assembly off the tank. Replace the new fuel pump in the assembly and install the assembly in the tank. Install the flange screws and torque to approximately 89 inch lbs using a crisscross pattern. If no torque wrench is available, tighten to a snug fit and stop.

(H) Afterwards, raise the fuel tank enough to attach fuel lines and vapor lines indicated above, item D. After connecting all lines, raise tank with floor jack to its original position "carefully" and utilize the new mounting bolts, securing straps in their original position and torque bolts to approximatlely 25-30 lbs torque.

(I) Install the fuel tank filler pipe per the aforementiond process reversed.

(J) Review your connections and then carefully lower the vehicle, use a gas container, input 4-5 gallows of gas and start the engine and check for leaks.

Wishing you the very best,

drprice

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