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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