just replaced fuel pump

[POSHO]

Well, I replaced my fuel pump today, and learned a lot. First off, I got a 190lph Walbro, off some website. Against everyone's advise, I decided to cut the hole under the seat for easier access; I also left all the gas in the tank. I got a general idea of where the pump was, cut a 1"x1" hole, took my bearings, and gradually increased it in size. I used WD40 during the cutting to minimize sparks, and had a fire extinguisher handy just in case, but neither was necessary. After I finally got a nice ROUND hole cut out, it was time to start disassembling. I loved the fuel line connectors, so much easier than GMs crap, but the retaining ring was a pain. After yanking the pump out, and taking the unit apart, I noticed that I was able to use the new fuel pump with the stock pulse dampener, and without any need for the extra hose. It also came with a new connector, to prevent the wires from coming loose. After putting on the new o-ring, it was a pain in the butt to get the retaining ring back in. After about an hour of fussing with that, I finally got it forced in, and all that was left was to reattach, cover, and start. The kit came with new clips for the fuel lines, and after some aluminum foil and duct tape I was ready to start the car. Turned the key a few million times to refill the lines (glad to hear the fuel pump whine again), and he started up beautifully. I was so happy that it was actually my fuel pump, and I'm glad to have it up and running again.
Just thought I'd share

 

[N3FOL]

Congratulations on the job well done. I will also have to start thinking of my fuel pump come spring or summer. So far, (knock on wood) my fuel pump is still alive and kicking. I had replaced my fuel filter numerous times ever since I bought my 1995 brand new. At the present time, I have 123K ...

Again, my congrats. Happy SHOing!

 

[Rockledge]

Congratulations on the fix. thumb

Don't want to sound like a ****, but I have to be candid with you. I think it was foolish to leave the gasoline in the tank. nono Draining the tank is simple enough to do, IMO.

Gasoline vapors (not just the liquid stuff) can ignite and cause quite a flare-up, to say the least. Having a fire extinguisher handy is a good thing, but it's not going to help you with that initial explosion.

When I was a young kid I saw two grown men get blown clear out of their boat and into the water when gas fumes from the boat's bilge ignited when one of the guys cranked the ignition immediatly after gassing up without first venting the bilge. Saw the whole thing with my own two little eyes. No bull, these guys were sent about 10 feet vertical and 20 feet horizontal. eek!

The two men were very lucky and ended up with some moderate burns and singed hair and eyebrows, etc. The boat was a total loss, burned for quite a while after someone smartly kicked it away from the gas dock and into the middle of the harbor. It's still a vivid memory for me today, many years later. I learned a lot about gas fumes and explosions and being in too much of a hurry, right then and there.

Glad to hear there was no SHO-Boom in your case.

 

[Rob94]

Not to mention using WD-40 to squelch sparks!!! WD-40 is highly flammable itself. You got lucky, VERY lucky.

 

[ckinart]

POSHO:
I got a general idea of where the pump was, cut a 1"x1" hole, took my bearings, and gradually increased it in size... I finally got a nice ROUND hole cut out, it was time to start disassembling.

I'm assuming you used this method because you weren't able to find specific measurements of where to make your cuts? (There used to be a webpage that's since been taken down that had pictures and specific directions on how to cut out an access panel that could be used to reseal the hole) What did you use to close up the hole you made? Any reason why you made your hole round? Just curious...

 

[NetNinja]

Thank God nothing happend to you dude!
At least you're alive to tell us about the Mod you did. wink

When we used to work on aircraft it was always the half empty tanks of gas we were most worried about.
It's the vapors that will blow you to ****!

 

[shojuan]

Rockledge:
Don't want to sound like a ****, but I have to be candid with you. I think it was foolish to leave the gasoline in the tank. nono Draining the tank is simple enough to do, IMO.

Gasoline vapors (not just the liquid stuff) can ignite and cause quite a flare-up, to say the least. Having a fire extinguisher handy is a good thing, but it's not going to help you with that initial explosion.

Gasoline vapors are far more dangerous than liquid gasoline. An empty tank full of vapor will make a far bigger initial explosion than a tank full of liquid gasoline. A full tank will burn longer however.

I flooded the area with CO2 when I did mine. But really, unless you cut a fuel line and your fuel sender to tank o-ring is intact you are pretty safe. After making an initial cut take a sniff down there (get your nose right next to the cut) to see if there are fumes. It's not too likely, especially considering that the top of the fuel tank is open to the surrounding air so vapors from a leaky tank seal aren't going to build up down there. Needless to say, if you smell gas after you make an initial cut then it would be a really good idea to not cut any more. Also you have roughly 1/2 to 1 inch of clearance IIRC between the fuel lines and the sheet metal where you will be cutting nearest to the passenger side. If that doesn't seem like much clearance and you don't trust your ability to keep your cutting efforts clear of those lines then do the "drop the tank" method instead. When I did mine I had no problem keeping my dremel cutoff wheel within a 1/16th inch or so beyond the sheet metal so the clearance to the fuel lines seemed like a lot to me. But anybody who even thinks they might be clumsy when doing the cutting should probably steer clear of the "cut a trapdoor" method.

 

[POSHO]

I don't really consider myself that lucky. I know it was kind of risky, but I think people have blown it WAY out of proportion. I took a sniff after the initial cut, definately a must. My first hole was small because, yes, the site was down, but the measurements are the same as a normal Taurus, so the supercharged 89 (?) page's measurements work out.
The reason I used WD40 was not in case of a fire, but to prevent it. It is flamable in a mist, but lighting a puddle is very difficult (I've tried many times). After the WD40 was sprayed onto the surface, it reduced the friction between the two contacting surfaces (sheet metal and cut-off wheel). It increases cutting time, but greatly reduces sparks.
As for fuel vapors, the night before I was watching that show 'Myth Busters' on the Discovery Channel, and they were doing an experiment considering igniting fuel vapors (to determine whether a cell phone or slight spark could ignite during a fill-up at a gas station). After I saw how much gas they needed, how much it had to be compressed, and how big of a spark they needed, I felt this project would be more than safe enough.
Good luck to everyone who tries this in the future, and watch out for them fuel lines.

 

[krupt89]

I'll take the extra 30 minutes to drop the tank. It really isnt that hard, and a 1000 times safer.

Glad to hear your safe though thumb