The installation duration of the Fuel Pump varies depending on the vehicle model, type of fuel pump and maintenance requirements. For subcompacts, if the fuel pump module is integrated into the fuel tank and the fuel tank is located underneath the rear seats, the routine replacement takes 1.5 to 2.5 hours and involves removing the seats (15 minutes), depressurizing the fuel system (5 to 10 minutes), disconnecting the fuel pipe circuit (10 minutes), and replacing it with a new pump (45 minutes). For instance, statistics of a specific auto repair chain shop in 2022 show that the average time to replace the fuel pump of a Toyota Corolla was 128 minutes. Among them, the delay caused by disassembly due to rusty bolts holding the fuel tank accounted for 23% of the fault cases, an additional 30 to 40 minutes of operation time.
Design variations of fuel pumps have a considerable impact on working hours. Fuel pumps designed module-wise (such as the Bosch EFP series) can save 30% of installation time. As they are pre-mounted with floats, filters and pressure regulating valves, it takes just 45 to 60 minutes to replace the entire module at one go. Split-type fuel pumps do require separate installation of the pump core, sealing ring, and filter, and the time taken increases to 90 to 120 minutes. One European car producer had mentioned within their technical bulletin that for SUV vehicles, they mounted the fuel pump deep down at the rear end of the fuel tank (35cm behind the fuel tank opening), and the time used in positioning the special tools equaled 18% of total operation time. If the operation error resulted in misalignment of the sealing ring, the rework rate was as high as 12%.
Maintenance personnel experience is as critical as the equipment level. Reflash only takes 3 to 5 minutes for the Fuel Pump control module (FPCM) with the same original diagnostic tooling (e.g., Ford IDS), but may take longer than 15 minutes with third-party tools due to protocol limitations for compatibility. Data from a US independent repair shop shows that the average labor time for veteran technicians to replace the fuel pump of a Chevrolet Silverado is 110 minutes (with testing), while for beginners it is 180 minutes. The error rate (like oil pipe leakage and incorrect circuit connection) has gone up from 5% to 22%. In addition, there are workstations with elevators that can decrease the process of fuel tank extraction by 40%, and to install the vehicle body Angle it will take 20 minutes more than in the case of trench excavation.
Unusual conditions of work will greatly prolong the duration of construction. For example, in the regions where salt corrosion is typical (like Canada’s Quebec province), the danger of fuel tank fixing belt rusting and destruction is 47%, and instances of removal of cutting tools account for 31%, with a mean addition of 55 minutes to work hours. If the wiring harness of the fuel pump will need to be replaced simultaneously due to aging (incidence around 15%), then the check on the wiring and circuit will require an extra 25 to 35 minutes. Industry statistics indicate the fuel pump replacement time for hybrid vehicles takes 45% longer than for fuel vehicles due to the blocking by the high-voltage battery pack of the fuel tank opening (accounting for 60% of the blocking area). For example, the average working time for the Lexus CT200h is 3.2 hours.
The compromise on cost-effectiveness has to be taken into consideration as well. When 4S stores adopt OEM fuel pumps (unit price 220-380), the total cost (including labor cost 120-180) is usually 340-560. However, independent repair shops using aftermarket parts (such as Delphi FG1618, with a unit price of 85) can reduce the total cost to 200-$300, but the fluctuation range of installation time expands (±25%). For instance, the Volvo XC90 experienced a change in the diameter of the fuel pump flange (after-sales part tolerance ±0.5mm vs.). (Original factory ±0.2mm), installation failure increased from 3% to 11%, thereby causing the ratio of secondary commissioning time increase to 19%. By optimizing the supply chain (for example, prior to storing model adaptation toolboxes) and normalizing operation process, the overall efficiency can increase by 15% to 20%.