Fuel Pump Removal and Replacement Process

Disclaimer: Links on this page pointing to Amazon, eBay and other sites may include affiliate code. If you click them and make a purchase, we may earn a small commission.

LowSHO

New Member
Joined
Feb 24, 2002
Messages
68
Reaction score
0
Location
Westchester County, NY
I just finished this process and I'd like to add a few tips to the very many helpful ones I found on this forum.

1. The fuel pump is on the passenger's side of the tank. The Shotimes how-to (very helpful) says you can get by without unbolting the driver's side strap. Not true! I put the floor jack on the driver's side and let the passenger's side of the tank down to the floor. I couldn't get sufficient access to the retainer ring otherwise.

2. The Walbro 190lph is short enough to fit in the bracket and retain the use of the surge dampener. I used the Auto Performance Engineering kit FPF016 for my '91 MTX. So I didn't use the connector hose and clamps which came in the kit.

3. Sdpatt and others have emphasized that with a little planning, you can run the gas tank nearly empty for convenience' sake. I didn't have that option. Get 12' of 1/4" fuel hose at your auto parts store and keep wiggling it around in there until you've got at least 9' in. There are a couple of places where the hose will get hung up on the way in. You have to get past those.

4. Go ahead and buy the replacement tankstrap bolts and clips. They are still available from the Ford dealers (about $18). I feel a little better knowing that the new bolts with uncorroded threads are holding up my tank. Also, 13 years from now, when I replace this pump, the bolts won't be any more difficult to remove than these were.

5. It took me 6 tries (over two days) to get the car to start and run properly. When I started it right after the replacement (and I turned the key six or seven times to pressurize the system), the car ran for about 1 minute and stalled. This was the symptom I had just labored mightily to fix - massive depression set in.

The next time it ran for about 3 minutes, then 5, then 10 and so on. It seems fine now, a day later.

So don't worry if the car doesn't fire right up - go inside, take a shower, think calming thoughts, then try it again.

6. Spend lots of time on this forum. The symptoms I saw led me to question virtually half of the onboard devices on my car. Read patiently through the posts, ask questions when you have them.

I would put the posts for APE, the Shotimes procedure, and sdpatt's helpful comments, but I'm not that skilled. Perhaps the moderators can provide the appropriate links.
 

masho95

got Zex?
Joined
Mar 5, 2003
Messages
2,039
Reaction score
4
Location
Chicopee, MA
The Shotimes how-to (very helpful) says you can get by without unbolting the driver's side strap. Not true! I put the floor jack on the driver's side and let the passenger's side of the tank down to the floor. I couldn't get sufficient access to the retainer ring otherwise.
I'd have to agree here. Maybe it's different on other cars but I was unable to get to anything without dropping the whole tank.
2. The Walbro 190lph is short enough to fit in the bracket and retain the use of the surge dampener. I used the Auto Performance Engineering kit FPF016 for my '91 MTX. So I didn't use the connector hose and clamps which came in the kit.
I also installed the Walbro 190lph unit, but was unable to get the pulse dampner to fit inline as is. Maybe the APE FPF016 kit was something I didn't have, but at any rate I couldn't get the pulse dampner to fit. Oh well.
4. Go ahead and buy the replacement tankstrap bolts and clips. They are still available from the Ford dealers (about $18). I feel a little better knowing that the new bolts with uncorroded threads are holding up my tank.
Would also agree here too. I didn't buy the kit and the driver-side bolt holding the strap was slightly stripped coming out and back in (but was able to hold proper torque). Better insurance that 18 gallons of gas is properly held up.
5. It took me 6 tries (over two days) to get the car to start and run properly. When I started it right after the replacement (and I turned the key six or seven times to pressurize the system), the car ran for about 1 minute and stalled. This was the symptom I had just labored mightily to fix - massive depression set in.
The next time it ran for about 3 minutes, then 5, then 10 and so on. It seems fine now, a day later.
So don't worry if the car doesn't fire right up - go inside, take a shower, think calming thoughts, then try it again.
Don't know why you had such a problem getting the car to start right up. After being pressurized that much it should start right up. That probably points to another weak point in your fuel system. How old is your fuel filter??
 

Blue-By-U

SHO Member
Joined
Oct 29, 2001
Messages
3,695
Reaction score
0
Location
CT
I think it's awesome when people post step-by-step procedures upon completing a SHO task. These come in handy when facing a unique problem that hasn't been addressed before (such as your start up problem) that provide convenient "heads-up" before diving right in.

I hope you still have your SHO in 13 years!!!

thumb
 

luigisho

SHO Member
Joined
Nov 2, 2001
Messages
13,265
Reaction score
5,143
Location
va beach,va
I've done this twice. The first time I dropped the tank and the second I cut through the floor pan. I was a little hesitant to cut into it but the amount of rust and busted fasteners last time lead me to try it. I'm glad I did. Quick and painless.

The APE Walbro SHO pump has the correct setup for the SHO so no trimming anything except if you want to replace the rubber connecting hose between the sender and the pump. Then it's cut to fit. Other than that, easy and started up first time out. It's much quieter than the last pump (which was a SLO replacement from AZ a few years ago). I think the kit is excellent for the price.
 

LowSHO

New Member
Joined
Feb 24, 2002
Messages
68
Reaction score
0
Location
Westchester County, NY
I replaced the fuel filter at the same time.

I think I have an ignition problem. After running fine for a couple of days, the car died (engine spinning, tach at zero) and won't restart. Codes indicated a stored 14 pointing to the CPS, but also a current 87 (primary fuel system failure)!

The old pump was definitely dying, and the new one definitely works, so I'll have to see if there's a fault in the wiring.

I was planning to do the 60k, top and front, later this summer. I guess I'll probably start next week.

In the meantime, my wife is getting used to taking the train.
 

autobahnsho

SHO Victim
Joined
Nov 21, 2002
Messages
852
Reaction score
0
Location
NY for now, WY for real
LowSHO:
I replaced the fuel filter at the same time.

I think I have an ignition problem. After running fine for a couple of days, the car died (engine spinning, tach at zero) and won't restart. Codes indicated a stored 14 pointing to the CPS, but also a current 87 (primary fuel system failure)!
I might be wrong, but the CPS code along with the tach at zero while the engine is cranking points to the CPS definitely being bad. (That's a fun job! I just did mine a few weeks ago..)

Have you checked fuel pressure at the valve on the fuel rails?
 

Freak SHO

New Member
Joined
Dec 12, 2002
Messages
82
Reaction score
0
Location
Witch City, baby! Salem,
luigisho:
I've done this twice. The first time I dropped the tank and the second I cut through the floor pan.
I remember seeing a step by step write-up of the floor pan cutting/fuel pump replacement procedure. Does anyone know the url offhand? It was on a green gen2 IIRC, and had clear, concise instructions with pics.

Thanks in advance,

Ben
 

ckinart

New Member
Joined
Jan 18, 2002
Messages
299
Reaction score
0
Location
Mississauga, Ontario
Ben,

Look here for instructions on how to replace your fuel pump by going in through the floor beneath the back seat. This post may also provide you with some useful info. I used this method to replace the pump in my '94 MTX, and it worked like a charm. thumb

*Edit*: If you decide to go this route, please be very careful, and think things through.

Good Luck!

<small>[ July 17, 2003, 12:20 PM: Message edited by: ckinart ]</small>
 

91 SHOplus

Sholess 4 Now
Joined
Jun 3, 2002
Messages
2,405
Reaction score
1
Location
North Jersey
Actually that brings up another thing. We used to have a "how to" section here with stuff like Fred's Y-pipe install, and Jay's fuel pump install instructions.

Can we get those back? shrug
 

Forum statistics

Threads
107,077
Messages
1,181,195
Members
16,141
Latest member
grapnelg

Members online

No members online now.
Back
Top