I added the ND pump for simple peace of mind, as it is basically overkill for my
current mods. The ND pump flows 70+gph (at 0psi (freeflow)), vs the 50 (?) stock,
and is there to prevent you from leaning out. I figured it was better to spend ~$200
than risk $2000 or more of damage to my engine. Again, this was overkill at this stage,
but I am an overkill kind of guy ;-)
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This is your basic starting point. Note that I did NOT have to remove the rear
floor support, only the pressboard piece and the spare tire. The fuel pump is
already unplugged.
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This is with the fuel pump cover removed completely - note I pulled the wire
out of the cover. It makes it a LOT easier to work with. BTW, the butyl gunk holding
the cover down can hold it down TOO well, and you may bend the cover getting it off. I
didn't have that problem, but others have. It also depends on how warm it is when you
are removing it - it comes off easy in summer, MUCH harder in winter.
The important parts?
- The blue piece is the check valve, you will need to bend the bracket towards
the electrical connections in order to pull the valve off. Then remove one
hose end and push the valve out of the way.
- The fuel fitting you will grow to hate is on the right of the hole.
- You will see 3 little rubber "knobs" - these are part of the gasket, and help
hold it on the pump cap.
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This is your closeup of the &(*#$ fuel line fitting. You will grow
to hate this thing. Note how mine is a little chewed up. I tried every
which way of getting that fitting loose, even using the right 14mm wrench,
and it would not come loose. I finally had to grab it with some large
vicegrips, and strain a few muscles to crack it loose. Then I took a Dremel
to the fitting, and smoothed it out - now it works with the 14mm flare wrench
again.
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Don't believe me and the many others on the Digest that say that fitting is hard
to crack loose? Here are 2 more pump fittings, one that came off relatively easily,
and one that had to be nearly destroyed to get it off. Note that the "easy" one
was still slightly mangled.
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If you still want to attempt to get this fitting loose, putting a wedge under the flare
wrench will help a lot (courtesy Tim Fisher). Otherwise, read on...
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(Addendum to the above - others have found it easier to disconnect the fuel
line farther forward near the front of the tank. There is a fitting there that seems
to be easier to crack loose for most people. However, it requires getting under the
car. My way, the fitting is much harder to crack open, but can be removed
easily in the future from above the car. It's up to you. If you DO undo the front
fitting, you can then undo the rear fitting once the pump is out, so in the future
you can use the rear fitting.
NOTE that 2nd gen cars should DEFINITELY use the forward fitting, as
the rear "fitting" may not actually be a fitting.)
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This is your &(*#$ fuel line fitting again. Once I got it loose,
I took off all six pump retaining nuts (one was hidden under the check valve and its'
rubber hose), and started to lift out the pump. Hm, some resistance, it's not coming
out. Lets do the intelligent thing, and check it out. Hm, feels like a gasket.
HEY!, so that's what those rubber knobs were for! The gasket tends to
stick to the tank, and the knobs hold it on the cap. Gently dislodge the gasket from
the tank, and wiggle the pump assembly in many different directions to remove it.
You'll figure out which directions when you get to this point.
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IT'S OUTTA THERE! If you are enterprising, you will stuff paper towels
in the tank opening, and clean the gasket surface. I was tired and pissed,
I didn't. DO make sure to stuff some paper towels in there to keep
stuff out until you put the pump back.
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Here is the pump, ready to work on.
Note a few things:
- The rubber gasket is in one piece, because I was careful.
- That bottom Philips screw will most likely not come loose using a
screwdriver. Grab it with pliers or vicegrips to crack it loose first.
- The rubber insulator will require a tiny bit of trimming to fit the
new pump properly. Do it, don't be lazy.
- The clip that holds the filter on is a pain to remove, but rock it off bit
by bit, DON'T just yank it, it will break, and you will be SOL.
- Obviously, don't bend the float pickup rod ;-)
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A note from Gino Valic in the Talon Digest:
"I recently discovered when installing my Nippondenso pump in a 91 gsx that the
O-ring needed for the pump is the same one used in the Walbro installation kit. I wound
up using the O-ring, retaining cap, and strainer clip for my pump installation. I have
found the part # for this O-ring which anyone should be able to find in Autozone or
PepBoys autoparts store. The O-ring is made by Borg Warner and the part # is 274571
Fuel injection seal. The list price is $4.25 and it cost me $1.98. The kit include
two O-rings so if you screw one up, you have an extra."
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