Fuel Pump Install

by: SamNavy


1. Remove carpet above package shelf and push back over the top of the top. Use a kitchen fork to pry up the quarter-sized black plastic push-bolts that hold the carpet down.

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2. Remove funky triangle shaped (small phillips) sheet metal cover.

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3. Take electrical clip off.

4. VERY IMPORTANT: OPEN YOUR GAS CAP AND REMOVE SEVERAL OF THE SCREWS ON THE PUMP BEFORE TAKING THE HOSES OFF!!! The tank will be slightly pressurized, if you crack the seal there should be no pressure in the line at all.

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5. Remove the rest of the screws from the cover and slowly remove the pump… careful not to bang anything around… hold it over the tank to let it drip for about 30 seconds, then slide it under a towel so as not to drip on the car.

6. Install your Walbro on the assembly. Use the image below as a helpful guide. You need to cut the inlet off the pickup tube in order to fit the fuel hose over the tube.

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7. Prior to reinstalling, inspect the rubber seal on the underside for alignment and condition.

8. Carefully feed the assembly back down in to the tank. Install screws in two rounds. First round, just get them threaded and lightly snugged. Once all of them are snugged, go around and crank them down… no sense in trying to warp the assembly plate.

9. Reconnect hoses. I replaced the stock pinch clips with small hose clamps to be on the safe side.

10. Prior to starting, I placed a small fan over the hole to make sure any drops or small amount of fuel that managed to pool in there somewhere was evaporated. Then I again positioned some towels under the lines in case on leaked… nothing to do about a hose blowing except shut it off immediately…. then clean.

11. Start engine. It might take a few seconds to catch as there will be no fuel pressure for a few seconds.

12. Reinstall metal cover and carpet… go for drive.

BIG ADVICE: Lay several towells of different sizes on the trunk-lid within arms reach. Lay towels along the backs of the seats if you want. NO SMOKING!!! If in the garage, have a fan blowing. Cover the hole up with a towel while you work on the pump assembly to minimize fumes and evaporation. Have a fire extinguisher close… in the kitchen pantry is not close enough.

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