Cutting an access panel under the passenger seat is strongly discouraged. Here's why:
* Fuel Tank Proximity: While the passenger seat is somewhat close to the tank, it's not directly above it. Cutting a hole might miss the tank entirely, creating an unnecessary hole, or worse, damage something else.
* Safety Hazards: Fuel systems are under pressure and contain flammable liquid. Improperly modifying the area around the fuel tank significantly increases the risk of fuel leaks, fire, and explosion.
* Structural Integrity: Cutting into the floor pan compromises the structural integrity of the vehicle, potentially affecting its safety in a collision.
* Complexity: Accessing the fuel pump even with the tank partially dropped is a complex job requiring specialized tools and knowledge to disconnect and reconnect fuel lines, electrical connectors, and the fuel level sender.
The proper way to replace the fuel pump is to:
1. Consult a repair manual: A Haynes or Chilton manual for your specific vehicle will have detailed instructions and diagrams.
2. Prepare properly: You'll need jack stands, safety glasses, gloves, fuel-resistant materials, and potentially specialized tools. Consider draining some fuel from the tank to make it lighter.
3. Lower the fuel tank: This involves disconnecting fuel lines, electrical connectors, and the fuel tank's straps. This is a more involved task and often requires special tools to carefully manipulate the fuel lines.
4. Access the fuel pump: Once the tank is sufficiently lowered or removed, you can access the fuel pump assembly, which is usually held in place by a retaining ring.
In short: Don't try to create an access panel. Replacing the fuel pump is a serious job best left to a qualified mechanic or someone with extensive experience working on automotive fuel systems. The risk of injury and damage far outweighs the potential time savings of creating an access panel.
