How to replace a fuel pump on a RT4wd

rti intrac

How to change your fuel pump, Its a easy job, 30-45 mins
Tools needed, 10mm socket, 17mm socket, flat nose pliers, #2 phillips screwdriver and a flat blade screwdriver

Start by lifting the rear seat up and pulling the carpet towards the front of the vehicle.
It should now look like this


Remove the cover closest to the left side of the vehicle and you'll see the fuel lines etc


Crack the outlet fuel feed. (leave it on for now) Unplug the plug for the fuel pump and remove the return line.


Crack the 10mm nuts around the top and remove them all.


Now you undo the 17mm bolt holdint the fuel line on. Be careful not to loose the crush washers. take the hose off and put the bolt & washers back on so they don't go for a walk.
Pull the whole assembly up and out. let the fuel drain out of the filter before completely removing it from the vehicle.


Now get your pliers and move the hose clamps to the middle of the hose. Gently hold the hose and rotate it on the pipe to brake the seal, move the hose to the top of the assembily so that its nearly off the pump. Grab the pump and move it up and pull it out. carefully remove the insulators from the wiring and unscrew the screws holding wires. They were very tight for me so be careful. Put your new pump in, connect the wires and it should look similar to this


Double check your wiring is all insulated, DON'T use tape as the fuel dissolves the adhesive.
put the pump assembly back in, do up the 10mm nuts and reconnect the fuel lines and plug. turn the key, check there are no leaks. put the cover back on and go have a beverage of your choice.

The_Head

Thanks for this writeup!

Jaker

I was begining to think I was on crack! Damned those pesky Honda engineers. Here's an example from a 1991 USDM Wagon DX. The RT might be different. Tell me what's missing:

bikewrench

That sucks^^^

My 90 usdm rt has it

rti intrac

I think on the 2wds it'll be easier to use a grinder carefully lol. The floor pan even has the cut outs for the cover...

superhatch

Thanks for the write up. Ill be using this for sure.

So did they just plan on needing to drop the whole tank to change the pump in the 2wd versions?

rti intrac

No problem, I thought i'd do a write up seeing as I had most of the pics.
I guess they did plan to drop the tank. I'd cut it personally Use a dremel or similar, the shape is pressed in the floor panel as per Jaker's pic

Jaker

I'm guessing that Honda decided that since there's no driveshaft in the way, dropping the tank on the 2WD wasn't going to be such a big deal. That portion of the floor panel is different from the RT in other ways as well, so the lip that is stamped into the metal around the opening for the fuel pump access is not a stretch because the stamping die is different to begin with.

If you want to open that hole, make sure the tank is dropped first. It'd suck big time to cut through one of those fuel lines and start a fire. I've been there, and was incredibly lucky that there was no fire. I don't want to ever be there again or hear about someone else's bad luck.

When I started the RWD build, I was removing the exhaust, and the over axle flange bolts were rusted and seized. I got out the angle grinder and started cutting the bolts/nuts off. When the last cut was finished, I stopped the grinder and was suddenly congnisant of the stream of fuel coming from the small cut I had accidentally made in the corner of the gas tank. About 3-4 litres of gas had spilled from the tank onto the floor before I managed to get the drain pan under the leak. The bigger issue was that there had just been a massive amount of sparks flying around from the cutting which had not managed to ignite the fuel. I was LUCKY!

JDMWago666

So is there anything in the way of dropping the tank on a 2wd Wagon? Am I going to have to drop the exhaust piping to get to my fuel pump? Asking cuz I may need to replace my fuel pump soon and want to be prepared for this next task.

Jaker

The exhaust on my FWD Wagon went around the gas tank. If your exhaust still follows the OEM routing then you should not have to drop it. Why not poke your head under there and check?

JDMWago666

I just wanted to ask before looking underneath. It's been weird weather over here and haven't even been able to touch my wagon because of it. Sun shine is no more, nothing but clouds, rain and snow. Thanks though

unlimited02

yea that makes sense b/c all ef's u have to drop the tank to get the fuel pump and yea... RT is way easyier just to go under the rear seats... and not drop the tank...

qnzjay69

Jaker wrote:

I was begining to think I was on crack! Damned those pesky Honda engineers. Here's an example from a 1991 USDM Wagon DX. The RT might be different. Tell me what's missing:

my 2wd 89 wagon looks like this also, so ur saying that i cant access the fuel pump through that opening???

Jaker

qnzjay69 wrote:

my 2wd 89 wagon looks like this also, so ur saying that i cant access the fuel pump through that opening???

You are correct. The only thing accessible through that opening is fuel level sender.

qnzjay69

Jaker wrote:

qnzjay69 wrote:

my 2wd 89 wagon looks like this also, so ur saying that i cant access the fuel pump through that opening???

You are correct. The only thing accessible through that opening is fuel level sender.

thanks alot bro, so all i have to do is remove the 2 fuel lines by the tank, and then unbolt the 2 hangers and it should drop?? do i need to put a special sealant or anthing when i put it back??

dukevonDANK

I hated dropping the tank on my EF...

Thank the all mighty engineer who put in the access panel on the RT's...

Haydz

EE2 = no panel
EE4 = yes panel
EF (anything EFi) = yes panel
EY = not sure