How to replace a fuel pump on a RT4wd
rti intrac
Senior Wagonist
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.
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.
Comments
My 90 usdm rt has it
So did they just plan on needing to drop the whole tank to change the pump in the 2wd versions?
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
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!
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??
Thank the all mighty engineer who put in the access panel on the RT's...
EE4 = yes panel
EF (anything EFi) = yes panel
EY = not sure