Fuel pump removal and install-tips?
 

Have the racetronix 255 pump, and a day off today. Having never installed or removed a fuel pump in my life, does anyone have suggestions or tips?

93 LT1

Do you need any instructions on how to get the pump unit out of the tank? Or are you good with that.

Follow the electrical instructions on the electrical connections.

Make some ohm meter readings before you take things apart so you know where the ground is on the external connector, sending (float) unit and pump motor. This is so when you install your new pump in the unit, you can make the same resistance measurements to make sure things are connected correctly before applying power.

If all looks gook apply power (key ON), the pump should run for 2 seconds, and check out the float unit for gauge movement.

Make sure any ground connections are good if removed/and or checked. Clamp the hoses well as instructions. And if all is good, install the unit back in the tank.

Don't drop anything in the tank.

I've done it several times. It is a 45 minute job-ish. Other than the step -by-step, here are a couple of things I learned along the way.

1) Read the FSM. Pretty straight forward
2) Cover your deck lid and make sure you only have about 1/4 tank of gas.
3) Loosen your fuel hoses prior to removing the mount bolts. You may need to push a small screw driver in between the rubber and metal if this is the first time off. Don't remove the hoses yet.
4) Remove the bolts and then "slide" the fuel pump to the left and then right to remove the loosened hoses. The extra distance moved (about 1.5 inches) will make a difference in disconnecting the hoses.
5. When you pull the pump out, you will need to "twist" it to the side and snake it out. It will make sense when you do it.
6. After you replace the pump but before installation, plug the harness in and flick the key briefly... you will want to hear the motor spool up to make sure it works.
7. during installation make sure you have the gasket notch lines up with the metal notch so you have a good seal.
8. Put some lube on the metal gas hoses and on the inside of the rubber gas hoses. It will aid in installation. Again, slide the pump side-to-side for ease of hose installation.
9. "Double clamp" the high pressure side of the fuel hose to make sure that the hose never blows off.

Also, if your gas gauge is wonky, you could clean the sending unit while the pump is out. It takes about 10 minutes and is pretty good PM. You will need to take a cotton ball soaked in WD40 and gently clean back and forth the calibration wires after you take the unit apart. Light sand paper on the contact point helps, but NEVER use sand paper on the sending wires.

Good luck!

Having a hell of a time removing the rubber fuel hoses. But I'll get them off. To those with the racetronix 255lph pump, are running stock size fuse?

My recommendation is to not change your fuse. I worry that if your were to have a problem, a larger fuse would cause your wire harness to melt.

Well top hose was a massive PITA. I had been trying to get it off since 4pm, roughly. Once I saw it had a cut from me pulling, I decided it was time to cut it off. Really had no choice. At least with the skill level I have. Looks I'll have to replace the whole fuel line:(


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Yes. Same fuse.

Here is a tip. Don't smoke while doing it. :rofl:

Don't worry about the cut line. I believe there is enough line to survive that small chink cut off. If you are really worried, maybe change all the lines? IIRC it might be better to take the taillight housings and the license plate out for better access.

Sounds good. It's at least an inch that had to be cut.

Will do, thanks for that. I'll post pics of the in tank connector. How about see what she does with the stock 10A fuse, and if it blows, go 15A?

1) The standard rule of electronic stuff is: The Load Is What The Load Is..

So, if you are changing fuses, be sure the wire gauge is adequate.

If you overload the wires, THEY become the fuse. This is "bad"

2) Don't use "continental" fuel line hose for anything. I had such a bad experience with them recently, I will never buy anything from them. Gates is it, and the ratings matter.

Good Luck!!! :cheers:

PS: It is like wiring your house.. An electrician can glance at your breaker box and just instantly rattle off:"Well that's wrong. That's the wrong breaker/fuse."

How does he know?

It is very simple: He knows the ampacity rating for the conductors he sees there.

Because we match safety devices (Fuses, breakers) to the safe load carrying capacity of the conductor in question..

A good idea.. ^^^

Check this .

I don't mean to nit pick on this point, so I'll say this and I will shut up..

I was a warehouse manager once, and I know when this was done because I know EXACTLY when the wiring was installed, and modified. A fresh space, done just for us.

I was sitting in my office when the roof caught fire.. I heard a VERY LOUD "FTTTTTTT!!!" sound and the lights went out. We rushed the customers out from the storefront in front.

What had happened was a years long overloading of the wires above the ceiling. It took years. Nothing was obviously wrong, but the electricians wiring didn't work, so the plaza maintenance man jumped two very large banks of lights together, then put in a larger breaker to keep it from tripping.

And it held for years.. It worked perfectly. You would neve rknow there was a problem at all.

Till that day the wires became the fuse, and they failed instantly from one end to the other and started a fire.

So, that's all I have to say.

Good luck!!! I wish you well.

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Anyone see anything wrong? Factory pump in these pics

I'd be concerned that the rust may effect electrical connections. A quick clean should do the trick.

Alright will do. How clean do we need the gasket surface? Would be pretty hard to clean without stuff falling inside.

I used this as an excuse to drain mine and sponge out little rust flakes and what have you.. You can reach pretty much the whole inside of the tank. If you see anything in there, it's a good time to remove it.

Otherwise, you could hold a rag in one hand and scrape into it with the other?

Yeah I got as clean as I could. Does anything look bad here?
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Not that I can tell.. Might brighten the contacts a little or put some OxGuard or something on them if you have it.