Here are some
helpful notes on swapping out the fuel pump - from when I did mine.
I'm
'fresh off the learning curve' on the fuel pump install so my apologies if
you already know this - but I didn't at the time (and did it 'the hard
way').
Rule #1: USE A
BATTERY POWERED LIGHT WHEN WORKING WITH/NEAR GASOLINE!
-
(One drop of gas
on a hot light bulb might result in the bulb exploding - and igniting
the 'recently vaporized' drop of gas... not good...)
I learned that you
don't want to remove the tank by removing the (2) 'cross bolts'
that hold up the rear-most ends of the tank straps. They are a pain to
get out and even worse to get back in!
I'm pretty sure the
factory uses the rear tank-strap bolts as hinges, and uses the front
tank-strap bolts to install the tank (unless they drop in the tank before
they fit the body to the frame).
Instead;
-
Raise,
and securely support,
the rear end of the car (D'oh!)
-
Flip your rear
license plate down,
open and then re-seal the gas cap (depressurize the tank)
and remove the (2) 10MM bolts holding the filler neck in place (leave
the gas cap on the tank - this way you can remove the tank without
having to worry about sloshing gasoline all over the place.)
-
From under the
drivers side, rear, of the car; un-clip the 3-wire electrical connector
for the wires that go up over the top of the tank.
-
Go to the FRONT
edge of the fuel tank and remove the (4) 7MM sheet metal screws from
each sheet
metal 'rock
shield' (between
the axle and tank) and
remove the
shields,
-
While you are
still at the front of the tank, reach up above the 'pumpkin' and un-hook
the wire 'clip' that holds the (3) fuel lines up to the body,
-
Support the tank (on
a jack with a good board to spread the load out)
and remove the (2) 15MM 'vertical' bolts from the FRONT ends of the tank
straps (the nuts are captive) and partially lower the tank,

-
Reach up over
the front edge of the tank and un-clip
the fuel and vent lines from the top of the tank (you'll need a special 5/16"
and 3/8" fuel
line tool, and something to catch some gas in)
-
Let the front
of the tank
the rest of the way down (the straps will hinge on the rear cross-bolts),
then slide the tank forward and out of the tank-strap cradle (be
careful with the filler neck/cap). Then push the straps back up and
drag the tank out from under the rear of the
car.
-
Un-bolt the ring
on the top of the tank (10MM?) and swap
out the pump (be careful not to screw up the sending unit - some
wiggling is necessary, but this
whole thing will
come out
of the tank)
-
Make sure you note
the orientation of the 'sock/strainer' on the original unit and put the
new one on the same way (to re-install, put the 'sock' on a table and
press the end of the pump onto the 'sock' - carefully, you only get one
chance at this).
-
I made a small
(aluminum) plate to cover the hole in the tank while I messed with the
pump to
reduce the gas fumes
- may not be necessary.
-
Reverse this to
re-install the tank.
HTH!
Guy
SSHVY 96
Diagonally
parked in a parallel universe.
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