Subject: TT fuel pump upgrade how to install

FUEL PUMP - First of all, its not hard, but is a very time consuming job. Pick a good Saturday to do it on. Start with pulling the carpet up in the back, and remove the rear padding. Find the two plug ins, one is for the fuel pump, and the other for the sending unit, unplug them both. One important thing before I continue, try to be almost completely empty before you start, it makes things easier, and the tank lighter. You'll have to jack the rear of the car up, I used some ramps, and backed it up on it. There is a shied under the car, that has to come off. Then, loosen the bolts for the two supporting straps, these must be removed from the car, once you loosen them a bit, you can remove them by wiggling them out. Now, the fuel neck, some people have undid it by the gas door, I tried, but had no luck on loosening the neck at that point. So, I removed the neck at the bottom, where it attaches to the tank (at the side). There is a rubber grommet / washer there, so be careful not to lose it. Try to support the tank with a jack to relieve some of the weight from it. Ok, now that the tank is loose, it will only drop down about 8-12 inches, because of all the lines that are attached. These are most easily gotten to from the top, thru the hatch. There are several lines attached, like 4 or so. Some are just air, some are fuel / fuel return. Be sure to either mark these, or remember them, just don't mix any up. This is probably the hardest part, removing and re-attaching the lines, with little room. Skipping ahead, once the lines are off, the tank will come down. Now, the fun part. Remove the screws hold the pump in, and it should slide out. It is kind of encased in a metal bracket, this has to come off. Once you take it off, the pump is encased in a rubber sleeve, this helps it hold it in the bracket. I slid mine off, to re-use it. The sleeve on the TT pump, is made with a tighter fit, and needs to be removed and discarded. I took a razor, and slit the side, and peeled it off. Take the old rubber, and slide it on the new TT pump...it might fit a little looser than the old one, but will be fine. Also, very important, your pump has as different type pickup at the bottom, with a screen, here's what you need to do. Keep the screen, and re-use it with the TT pump. But, the long like pick up tube needs to be cut, like almost flush with the plastic base, its plastic, so just use a sharp razor, and it should slice thru it. This must me done, in order to fit the pump into the tank again, as the TT is a little taller with this plastic pipe. You have to swap the electrical connections, just make sure you get the + / - right. Once your done with that, it should basically look like when you started. Now, you need to wiggle the pump back in the tank. Everything from this point on is pretty much the reverse of taking it out. Again, juggling the tank, on the Jack, and attaching the fuel lines and hoses are the most aggravating part. Also, when you attach the fuel neck back to the tank, be sure that the washer / grommet is seated in the groove, or you will have leaks. Just be sure to put everything back the way it came off. If you start the job, and have a problem, and need some help, feel free to ask. Its been a while since I did this mod, and I may have forgotten something. Good Luck !



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