READ THESE INSTRUCTIONS and the instructions that came with the new pump, COMPLETELY a few times at least BEFORE STARTING!
1, Locate the access cover on the passenger side of the boot floor, unscrew and remove the cover.
2, Disconnect the power wires to the fuel pump. (It's the larger of the two sets of wires and connector)
3, Start the car. It should run for about 1 second until it uses the fuel in the lines. Be sure to turn the key off and remove it completely after this step. Disconnect the negative terminal on the battery now too.
4, Pull out the other wiring connector (fuel gauge sender) and undo the clamps holding the fuel lines and remove the lines tucking them away on either side. There should be minimal fuel spillage if you did the previous steps correctly.
5, Unscrew (counter clockwise) the ring holding the fuel pump assembly in the tank. This is always difficult and you can buy tools to make it easier if you like. Otherwise stick to grunting and groaning like most people do.
6, Take out the pump assembly being careful not to drop any tools or debris into the tank. Take the pump assembly well away from the car NOW.
7, Remove the old pump. Any moron should be able to work out how to do this step.
This is what you should have once the pump is removed... (NOTE: this is an EA pump assembly, later models differ slightly)
PLEASE BE EXTREMELY CAREFUL WITH THIS PART: Make sure that the whole assembly is dry and not covered in fuel still. You could use a hacksaw to minimise the risk of fire but we used an angle grinder. We had no problems. BUT THIS IS WHY IT'S IMPERATIVE THAT YOU MOVE AWAY FROM THE OPEN FUEL TANK TO DO THESE STEPS!
8, You need to cut these parts off the pump assembly...
The two little bits are what the screw goes into on one side of the clamp that held the factory pump in place and the other bit is the hook that the other side of the said clamp hooks onto. It's pretty obvious where the largest part came from...
9, Take a hose clamp the same size as the ones used on your top radiator hose and clamp the new pump in place. Use the stock rubber insulator (trim as necessary) around the new pump. Use the fixed part of the stock clamp that is still attached to the assembly to put the hose clamp around. Secure everything firmly by tightening the screw on the hose clamp.
You should be left with it looking like this:
10, You will need to crimp a new spade terminal on the end of one of the wires. Red is positive and white is negative, the terminals on the pump are clearly marked too. The stock pump has one large and one small spade connector the new pump doesn't. Make sure you crimp it properly using a proper crimper. I imagine if you make a bad connection it won't just result in the pump not working but a spark being created and your car blowing up!
11, Install a new piece of proper EFI fuel line between the new pump and the feed line on the housing. DON'T REUSE THE OLD PIECE! Install the pickup filter that came with the new pump to the pickup on the bottom of the new pump.
12, Double check everything. Take your time doing this! You don't want to rush anything and have to do something over again or worse still cause your car to explode.
13, Re-install the pump assembly. Remembering how everything went before you removed it. Double checking everything as you go... No mistakes remember!
14, Connect the negative battery terminal back onto the battery. Turn the key on and you should hear the pump prime. Turn the key off again and wait 30 seconds. Turn the key on again and listen for the pump to prime. the pressure should be up in the lines now and you can start the car. It might take a few more cranks than usual until the fuel gets to the engine properly but this will only happen once if you have done everything right.
15, Enjoy!
If you have any questions feel free to ask. If you're unsure about something definitely ask. If I've missed anything tell me and I will amend the tutorial.
Discuss...
Cheers,
Brett
A big thanks to Kelvin (aka turbodrift) for doing most of the work with this on my car last weekend. We're a team, I tell him what to cut and he cuts it. He tries to be funny and I pretend to laugh. Go team!
