[jem270]

Fuel pump install problem.

I bought the dealer fuel pump.

Part #25179344 $540.00 (I paid $440.00 by whining and asking for wholesale price)
MODULE, F/TNK F/PMPSENDER & PUMP. W/SEAL. CODE WFR.
After VIN 238198

I have the 2nd design pump so this is my part number.

It took me about 2.5 hours. Most of the time was trying to install the new one. I started with ¼ tank of gas per service manual.

I started by taking all the carpet out of the trunk. I laid some carpet on the trunk so I could lay and reach the pump. I took off the access panel and the pump was covered with dirt/grime. I sprayed it with some cleaner and hosed it off. It looked almost new. I then disconnected the battery and released the fuel pressure at the Schrader valve and loosened the gas cap.

I marked the lines before I started to remove them. I figured out how to release the outer lines by squeezing the clear parts which are clips. I had to reuse them because they did not come with the new pump. The inner line was strange in that there is a black ring on the end you have to squeeze to release it. I had to use a small screwdriver to help pry it off.

I used a pair of snap ring pliers to remove the snap ring. The pump was stuck down. I had to use a screwdriver to carefully pry it up. I guess the old O ring was holding it in. I pulled it straight up and tilted it slightly so the float will come out. I had looked at the new one to see how to tilt it.

I looked inside the tank with a flashlight and I was surprised how clean and rust free the tank was.

I took the new pump and tilted it to clear the float and put in the tank. The O ring on the new one was already in position on the new pump. Service manual said to install O ring on the tank before you install pump. I moved the O ring to the tank and pressed the pump down. It would not go all the way down. I tried many positions and it would go almost all the way but would not go the last 1/8 inch down to clear the snap ring. It was difficult to put much pressure on it while lying on my stomach. I also tried to install the pump with the O ring already on the pump and had the same problem.

I decided to pull out the rear seat bottom and top. The bottom just pops out and the top is held on by two nuts on the bottom. There was a foam flap on the back and I pulled it from the bottom and just tucked it under the windshield.

At this point I slapped myself because it was MUCH easier to get to the pump. I just sat cross-legged and was able to do everything. I still had problems getting the pump all the way down. I guess the problem was compressing the O ring. I got my son to push down on the pump with the back of a hammer and put pressure on it and I moved the snap ring around and got it into place. I had him put minimum pressure on it because the pump is made out of plastic and expensive. The snap ring has to be exactly in place because it will only fit one way. There is a little lip it has to clear. Look at the old one before you take it off.

I then took the old clear clips off the old pump and installed them on the new one. Look at them before you take them off. They only go on one way. I then attached the 3 fuel lines and the electrical connection.

I hooked up the battery, tightened the fuel cap and turned the key to run a couple of times and let the fuel system pressurize. I started the engine and it ran. I checked for leaks and everything seemed good. I put everything back together and told my son to test drive it and fill it up with gas.

He called from the gas station and said gas was flowing out of the bottom of the car. He drove it home and I took out the back seat bottom and top. I took off the inspection cover and the top of the pump was wet with gas. It appears that the O ring must have gotten pinched and did not seal. Next step is to take it back off. Problem is tank is now full of gas. I dried the top of the pump off and drove the car about 20 miles. The top of the fuel pump is still dry but the sun has set and it is now dark. I will drive it again today when I get home from work and try to burn off more gas. Service manual said to have less than ¼ tank of gas in fuel tank.

I will take the pump off again and this time I will lubricate the O ring with Vaseline (I read somewhere that it helped). I will try to reinstall the pump with the O ring already on the pump. My legs are still sore from lying in the trunk. Wish me luck.

Any opinions/advise welcomed and much appreciated...