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1. First drive the car until you are under 1/4 of a tank. I found
that at about 1/8 tank, no fuel spilled out when I removed the hanger.
2. Jack up the rear passenger side of the car and properly put
jack stands in place. Remove the rear tire/
3. Remove the external pump, hoses, and fuel filter.
4. There is a metal lock ring that hold the hanger in place.
This needs to be rotated to remove the hanger. Use a hammer and brass punch,
to prevent sparks.
5. Disconnect the wires leading to the hanger.
6. Pull the hanger assembly out of the fuel tank. If any fuel
begins to leak, catch it in a suitable container, don't just let in run
into the soil. Also if you do this in your garage, be sure to ventilate
the area since the fumes will build up.
7. The hanger assemlbly is fairly long, and it takes some good
angling to get it out of the tank if the car isn't too high off the ground.
Be careful of the fuel level float when you take the assembly out.
8. My internal pump was marked 1989 so the assembly might have
been serviced at some point. I'm not sure if my car got an updated hanger
or not.
Stock
pump hanger and new hardware.
9. Remove the two screws holding the pump to the hanger and the
fuel line running to the pump.
Internal pump, retainer, and new pump.
10. As you can see the new pump is exactly the same, just a little longer.
11. The retainer will be a little too short with the new pump. Be sure to use the new O-ring that seals the front of the pump to the pickup.
12. Using a dremel, I opened up the retainer enough to slip over the pump body.
13. Now I needed some way for the retainer to still hold the pump in since it was no longer pushing against the rear of the pump. I used the foam that came in the kit but if I did it again I would use a hose clamp on the body to keep as much of the pump body in contact with the fuel to maximize cooling.
12. Reinstall the pump onto the hanger, put on the new filter sock, hook up the new fuel line, hook up the new power connector, and clean any junk out of the return line.
13. Reinstall the hanger into the tank.
14. There is a pressure dampener on the external pump that some people have removed with no ill effects, I decided to keep it but since it is threaded onto the external pump, I had to find a way to hook it up without the external pump being there. I used a 1/8" NPT coupling and male nipple to finish the job.
15. Hook up new fuel lines out side of the tank, new fuel filter, and reconnect the pump wiring and you're ready to go. While the car is still up, turn the key to IGN to prime the pump and make sure nothing is leaking under the car before going for a drive. Test out the pump on the road and slowly bring into boost to verify fuel delivery via A/F guage, plugs, audible detonation, or EGT. All should be well with correct install. Happy boosting!
