Thread: 04/05 fuel pump install- Fuel pump access in trunk

This is a write up for all of us 04+ guys with fuel pumps that have access in the trunk. For the later 05-08 gp's with the pump in the tank, the pump should still be the same, but getting it out will be up to you. Can't help you there. I installed a walbro 255lph pump i got from intense. Works great with about 400 miles on it since last week. It's noticeably louder at start up, but not annoyingly loud. I won't go into how to do the Fuel pump rewire to the fuse box, but i would recommend doing that as well at the same time.

Step 1. Release fuel pressure from fuel lines. Best way is to start the car then pull the pumps fuse in the box under the hood. When the car dies, you're ready.

Step 2. Unplug negative battery terminal.

Step 3. Clear at least the forward portion of your trunk so you can reach the pump. Get in your backseat behind the driver side, put the other side access to the trunk down.

Step 4. Pull up carpet, and remove access cover to the fuel pump. Screw thingys are 10mm i believe. I just hit em with a pair of pliers since they're not really tight, at least on mine.

Step 5. Once you see your pump, remove the three fuel lines coming out of it. The outer two are quick releases. Push in the blue taps on both sides and they slide right off. The middle one you just have to squeeze and pull off. It might take some work to get the middle one off. It did for me. Some fuel will spill out. I had a couple of towels with me that i didn't mind throwing away for this reason. I put one on the laid down backseat and used to the other to try and clean it up when it spilled. The car smelled like gas for 3 days, but it's fine now.



This is what the pump looks like sitting in the canister in the car.


Disconnect the lines

Step 6. Disconnect the wires going to it. You can do this first before you disconnect the lines doesn't matter. Your choice. Put them to the side of the pump area. They'll slide down by the tank a bit, just make sure they don't go too far.



This piece holds the pump down in place. I used a screw driver to pry it left i believe. Get it off, and then the canister is ready to come out.

Step 7. Take Metal holding piece off. Once it's off, the canister can come out. You're going to have to twist the canister to get it out. Just be careful. I had a bucket standing by in the backseat on the laid down seat. I put it in there. Some fuel will still be in it and leak out, that's why i did it. You'll spill some, get over it.


Canister out.

Step 8. Once your canister is out, you need to set it some place where you can go to work on it. Get yourself a chair, it's easier to sit and do this crap. You'll probably need a philips screwdriver, pliers and some knife to cut away some wires. Probably some electrical connectors and tape too.



Step 9. Disconnect this wire that goes into the top of the canister. There are two connectors, a red and grey. Take them out then get the plug out the top. I had to pry mine out with a screwdriver. It was in there well. Get it out so you can separate the canister in two. The bottom part of the wire unplugs easy, but the plug itself will stay connected to the bottom of the canister as two of the wires from it go to the level sending unit or whatever it's called.



Step 10. Once the plugs are disconnected, separate the canister in two. There are two buttons that you push in to do this on the sides. Use your screwdriver, push them in, then pull the thing apart.



Canister separated

Step 11. With the canister separated you can go to work finally. Take the old fuel line off pump and off the top of the canister. If you're planning to reuse it be careful with it. Honestly, i'm not sure how this would go, cause mine was stuck on there like glue. I had to cut it off. Either way, cut if off and use a new line or get it off and reuse, either way get it off the pump and the top of the canister. Once it's off get the old fuel pump out of it's rubber sleeping bag and you're done with it.



Step 12. Once the old pump is off, it's time to focus on the new one. I got a new sock with my pump, so the old one was trash too. Here's the new pump vs the old. New left, old Right

Step 13. The wires for the old harness didn't work with the ones for my new pump. So i had to splice them together in a Frankenstein way to make it workable. DO the black to black, red to grey. Splice them using a connector or tape or like me, both to be sure.





Step 14. Once the wires are splice together, You can leave the plug alone. I have it plugged in already in the pics, but don't do that yet. Just let it hang out while you position the pump in the canister and get the fuel line back on. Put the new sock that came with the pump on the new pump. Put the rubber end and sleeve from the old pump on the new one and attache the line to the new pump.

Step 15. Put the pump in the bottom of the canister. Note here that i never touched the sock on the exterior of the bottom of the canister. Just the one of the pump itself.
The sock that came with my new pump is bigger than the one with my stock one. Just shove it in the bottom, it'll bend but fit.


Pump in, not connected yet

Step 16. Put the top of the canister back on. A little force is required as it is a tight fit. Line everything back up, it'll only go one way and put it back together. AS YOU'RE DOING THIS CONNECT THE FUEL LINE TO THE TOP OF THE CANISTER. Basically put the pump in the bottom, line it up, START putting the canister back together, then connect the line to the top as you're doing it. The line goes on rough, meaning it will take some twisting and some force. This is good as you don't want it to slide off easy, so it shouldn't go on easy. Get it on all the way to the top then snap the canister back together.



Step 17. With your canister connected back and the line back on the pump and connected to the top, connect the spliced together harness to the pump and the top of the canister. Put the connectors back in the plug and you're good to go. The canister should be ready to go back in. New pump installed.





Put it back in the same way you took it out, reconnect your lines to the top, and then sit it down in the hole. Mine took a bit of work to get it back in the hole and get the metal holder back on properly. Just take your time and keep force on all sides of it. Mine kept popping out of one side when the other went in. Stay with it and you'll get it.

Once you get the metal cover back on put the plugs back in the top. You can wait to reconnect the fuel line til you get it situated in the tank too if you want, doesn't really matter once it's in. Close up the access cover, Reconnect the battery terminal and fuel fuse, prime the pump and see if it works.

DONE.

I removed my stock sock, opened the hole up larger, and made it shorter, and stuck my pump in there... the sock slides onto the end. This way, it will draw fuel from the very very bottom, like stock. I'd imagine this setup will be sketchy below 1/4 tank, no?

No clue I haven't ran it that low yet. But it should be fine as I believe the new sock still reaches the bottom of the canister. I plan on carrying my 5 gallon can with me and seeing how far I can take it down now. I'll report back.