Fuel pump removal Gen4 Sedan

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Fuel pump removal Gen4 Sedan

Postby zero_cool » Mon Dec 30, 2013 9:27 pm

Fuel pumps and me.
Alrighty kidlets, I had a quick search around the forums for a walk through with changing fuel pumps on my Gen4 sedan but my forum master search skills were not so good (always hated PBPBB search)

Can someone offer a quick rundown on the removal of the pump?

In the coming weeks I'm going to be replacing the pump with a DW65C in prep for a re-tune of the H6

A link if there is an existing walk through would be fantastic.

I'm assuming the tanks location is under the back seat?

Remove the baffle on the interior,
remove 2 fuel lines both feed and return,
crack the seal on top of the tank and pull out the entire pump assembly, remove from bracket and refit new pump? being careful not to bend the fuel level sender unit (if it is on the cradle?)

Am I close?

Give me a 90's Laser / Mazda and I could tell you exactly where each component goes / is
but on the scoobys I'm clueless since i've only owned it for less than 2 months.

Thanks in advance :) :twisted:
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Re: Fuel pump removal Gen4 Sedan

Postby KiDo_Tuning » Mon Dec 30, 2013 10:07 pm

zero_cool wrote:Fuel pumps and me.
Alrighty kidlets, I had a quick search around the forums for a walk through with changing fuel pumps on my Gen4 sedan but my forum master search skills were not so good (always hated PBPBB search)

Can someone offer a quick rundown on the removal of the pump?

In the coming weeks I'm going to be replacing the pump with a DW65C in prep for a re-tune of the H6

A link if there is an existing walk through would be fantastic.

I'm assuming the tanks location is under the back seat?

Remove the baffle on the interior,
remove 2 fuel lines both feed and return,
crack the seal on top of the tank and pull out the entire pump assembly, remove from bracket and refit new pump? being careful not to bend the fuel level sender unit (if it is on the cradle?)

Am I close?

Give me a 90's Laser / Mazda and I could tell you exactly where each component goes / is
but on the scoobys I'm clueless since i've only owned it for less than 2 months.

Thanks in advance :) :twisted:


Correct on under the rear seat.

Remove the rear seat, it lifts up quite easily once the front clips are freed up(push front of seat towards rear of car to free them)
Remove Fuel Tank Cover with four 10mm bolts
Disconnect the wiring loom
Start car which will remove fuel rail pressure from fuel lines

Undo 3 fuel lines(Pressure, return and ancillary side hose
Remove 8 bolts holding down tank cover
Lift up the unit and twist it to get the fuel level float out

Enjoy the absolute 'pleasure' of removing the old pump from the cradle/filter assembly, there is 2 plastic clips holding stock pump in place. Look at the DW65c and you will see their location
ENSURE YOU HAVE THE BLACK O RING IN PLACE AT TOP OF FUEL PUMP BODY WHEN REFITTING FUEL PUMP TO THE CRADLE!!!!!!
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Re: Fuel pump removal Gen4 Sedan

Postby mynameisdaniel » Mon Dec 30, 2013 10:22 pm

This guide is VERY detailed and applies almost perfectly to the liberty.
http://forums.nasioc.com/forums/showthr ... ?t=2303133

Cable ties through all the clips makes it a not too painful job to do by yourself :)
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Re: Fuel pump removal Gen4 Sedan

Postby zero_cool » Tue Dec 31, 2013 9:36 am

KiDo_Tuning wrote:
zero_cool wrote:Fuel pumps and me.
Alrighty kidlets, I had a quick search around the forums for a walk through with changing fuel pumps on my Gen4 sedan but my forum master search skills were not so good (always hated PBPBB search)

Can someone offer a quick rundown on the removal of the pump?

In the coming weeks I'm going to be replacing the pump with a DW65C in prep for a re-tune of the H6

A link if there is an existing walk through would be fantastic.

I'm assuming the tanks location is under the back seat?

Remove the baffle on the interior,
remove 2 fuel lines both feed and return,
crack the seal on top of the tank and pull out the entire pump assembly, remove from bracket and refit new pump? being careful not to bend the fuel level sender unit (if it is on the cradle?)

Am I close?

Give me a 90's Laser / Mazda and I could tell you exactly where each component goes / is
but on the scoobys I'm clueless since i've only owned it for less than 2 months.

Thanks in advance :) :twisted:


Correct on under the rear seat.

Remove the rear seat, it lifts up quite easily once the front clips are freed up(push front of seat towards rear of car to free them)
Remove Fuel Tank Cover with four 10mm bolts
Disconnect the wiring loom
Start car which will remove fuel rail pressure from fuel lines

Undo 3 fuel lines(Pressure, return and ancillary side hose
Remove 8 bolts holding down tank cover
Lift up the unit and twist it to get the fuel level float out

Enjoy the absolute 'pleasure' of removing the old pump from the cradle/filter assembly, there is 2 plastic clips holding stock pump in place. Look at the DW65c and you will see their location
ENSURE YOU HAVE THE BLACK O RING IN PLACE AT TOP OF FUEL PUMP BODY WHEN REFITTING FUEL PUMP TO THE CRADLE!!!!!!



Wow.. :bad:

Here I was thinking it was fairly simple
then I look at all the pretty pictures from mynameisdaniel and I just had "nopenopenope"

I see this taking more than 30mins to swap over with lots of swearing.
ahh the little O ring! I know them all too well :)

Thanks alot!
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Re: Fuel pump removal Gen4 Sedan

Postby mynameisdaniel » Tue Dec 31, 2013 9:51 am

That guide does make it look more complex than it is, but is useful. It's really just a few screws, lots of clips and a few plugs. Probably about an hour to do for the first time. Took me a bit longer as I'm pedantic and work slowly, making sure everything's greased and sitting right.
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Re: Fuel pump removal Gen4 Sedan

Postby dr20t » Wed Jan 01, 2014 9:19 am

The hardest part is prying the top part of the cradle from the bottom bucket, due to the five clips holding it in which need to be simultaneously depressed to allow it to come free.

The rest is easy
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Re: Fuel pump removal Gen4 Sedan

Postby Out6ack » Wed Mar 26, 2014 9:09 pm

I installed a DW65C + new filters (main & pre) last night.
Piece of cake with the help of the tutorials above so thanx heaps for that.
I had 4 flat blade screwdrivers at the ready for the clips which made it quite easy & the whole job wasn't hard at all so don't be put off by it if you're contemplating a DIY install.
The only part I found frustrating was trying to install the tiiiiiny little supplied circlip that retains the pre-filter. I ended up using the original from the OEM pump.
Again, thanx for the help by previous posters.

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Re: Fuel pump removal Gen4 Sedan

Postby Out6ack » Sun Jul 13, 2014 2:42 am

**Additional info on CRITICAL o-ring sizes and placement.**
(Copied from E85 H6 = WINNING thread.)

Out6ack wrote:This was bugging me so I removed the DW65 tonight to triple check everything. I also had my laptop handy to display a bloody good downloaded workshop manual that I'd recently bought online -opened at the fuel pump page.
I noticed something within this manual's guide that I hadn't seen mentioned in either Club Lib's or NASIOC's walk through on the subject -both of which I solely referred to for my guidance during initial install.

The 4 o-rings are 2 different sizes (2X7mm + 2X8mm internal diameter) and MUST be installed to their correct locations or you might suffer pressure retention issues ..like I did.

I'm not to proud to raise my hand and say 'I Phukked Up!' in this instance.

I had overlooked the 1mm diameter difference between these o-rings and didn't have them located in their correct position. The walkthroughs I mentioned were very helpful and excellent guidance, but please be aware for future reference that this critical o-ring diameter and placement location is not mentioned in either guide.

So here tis..

Place a 7mm ring on the BLACK connector.
Place an 8mm ring on the WHITE connector.
image.jpg
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Place an 8mm ring on the DW65c pump. (This is where you can put the additional 2nd ring.)
Align the 4 slots on the pump spacer sleeve with the 4 ribs within the basket. (Well, I did anyway..)
image.jpg
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Place 7mm ring on lower BLACK connector that feeds to the base of the basket.
image.jpg
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Done.

And umm yeah, priming problem tested ...and confirmed SOLVED.
Starts up quickly whether primed or not.

**I can only speak of my own findings, but strongly suggest to anyone having priming/starting/pressure issues to quickly check the correct placement of these o-rings.**

I'll be the one in the corner with a Dunce hat on.. :roll:


Jay.

Last edited by Out6ack on Wed Jul 16, 2014 11:21 am, edited 3 times in total.
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Re: Fuel pump removal Gen4 Sedan

Postby Out6ack » Sun Jul 13, 2014 5:24 pm

Also..
dr20t wrote:The hardest part is prying the top part of the cradle from the bottom bucket, due to the five clips holding it in which need to be simultaneously depressed to allow it to come free.

The rest is easy


Get 5 medium sized cable ties. Pry open a clip with a screwdriver and push a cable tie DOWN through the gap. Do this for each clip. Saves approx $43 in swear jar fees..
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Re: Fuel pump removal Gen4 Sedan

Postby kiwigene » Mon Jan 12, 2015 9:45 am

For you guys that have done the fuel pump/filter change, what grease did you use on the o-rings?

I assume it has to be fuel and ethanol resistant.

I see from the NASIOC thread there is something called Pro Circuit Seal and O-ring Grease PC-03 which came with the DW65c.
But my replacement fuel pump didn't come with any grease.

Is there a type/brand of grease you can get from SuperCheap/Repco which is equivalent?
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Re: Fuel pump removal Gen4 Sedan

Postby alexeiwoody » Mon Jan 12, 2015 10:20 am

kiwigene wrote:For you guys that have done the fuel pump/filter change, what grease did you use on the o-rings?

I assume it has to be fuel and ethanol resistant.

I see from the NASIOC thread there is something called Pro Circuit Seal and O-ring Grease PC-03 which came with the DW65c.
But my replacement fuel pump didn't come with any grease.

Is there a type/brand of grease you can get from SuperCheap/Repco which is equivalent?


Just use vaseline dude. Grease is there to aid the sliding of the ring in between the components, to stop the ring catching on the walls and deforming or tearing during installation. You don't need it to last forever in there or be E85 resistant, it's the oring that does the sealing, not the grease.


If anyone here has installed a DW320/340, you'll think the dw65c is a walk in the park! :lol:
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Re: Fuel pump removal Gen4 Sedan

Postby slipperysnake » Sun Nov 10, 2019 4:45 pm

Very helpful, thanks!
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Re: Fuel pump removal Gen4 Sedan

Postby bigBADbenny » Mon Nov 11, 2019 7:59 am

Not sure if I missed it in the advice above, but do start with a nearly empty fuel tank!
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