fuel pump replacement

[marshall smith]

hi all
i have read your posts copied a few threads and started out to replace the fuel pump on my 03 mm.
every thing looked great till i discovered there are 2 plugs of wires connected to the fuel pump.
the 8 plug big one was easy enough to disconnect. the 3 wire one that wraps over the passenger side of gas tank has a few challenges associated with it.
i can't get two hands in their after removing the tire. i assume you push one side facing the front of the car while holding the pipe its attached to and pull away.
ANY THOUGHTS OR IDEAS FOR THE REMOVAL WILL BE DEEPLY APPRECIATE
ALOHA
MARSHALL
:violin:

[Curless]

hi all
i have read your posts copied a few threads and started out to replace the fuel pump on my 03 mm.
every thing looked great till i discovered there are 2 plugs of wires connected to the fuel pump.
the 8 plug big one was easy enough to disconnect. the 3 wire one that wraps over the passenger side of gas tank has a few challenges associated with it.
i can't get two hands in their after removing the tire. i assume you push one side facing the front of the car while holding the pipe its attached to and pull away.
ANY THOUGHTS OR IDEAS FOR THE REMOVAL WILL BE DEEPLY APPRECIATE
ALOHA
MARSHALL
:violin:

I just replaced my fuel pump last week, I did not remove the tank from the car. The wires that wrap around the side of the car, I took them out of the harness at the main connector and left the three of them in the car when I did mine.

[captain]

speaking only for myself....
Used a nylon load strap...to pull the right exhaust tip to the right...some inches= clearance
loosened the tank.. In the work area...Alot....but not off.
cut a wire or 2 on purpose.
jiggled and wiggled and out she goes.
Damaged the sock....Dont do that. Hard to find a replacement.
Most interesting thing....All those wires swimming in gas!! Who was the first guy to test that!!

[marshall smith]

I just replaced my fuel pump last week, I did not remove the tank from the car. The wires that wrap around the side of the car, I took them out of the harness at the main connector and left the three of them in the car when I did mine.
when you left them in the car you had to take the cover up to the 8 pin connector apart. did you just tape it back together.
or did you cut any wires?

[marshall smith]

speaking only for myself....
Used a nylon load strap...to pull the right exhaust tip to the right...some inches= clearance
loosened the tank.. In the work area...Alot....but not off.
cut a wire or 2 on purpose.
jiggled and wiggled and out she goes.
Damaged the sock....Dont do that. Hard to find a replacement.
Most interesting thing....All those wires swimming in gas!! Who was the first guy to test that!!
well this weekend is the task. so if all else fails loosing the tank and cutting a few wires does sound like one way to do it.
i was wondering about the wires swimming in the gas?

[camelgrundle]

as long as their is a good connection you will have no problems with the wires in the gas it just seems scarier than it is. I just used a connector for the wires crimped them together and heat shrink tubing around the connections and no boom yet lol

[captain]

I studied the wires in gas tank thing on the internet. Its some kind of mad science involving ratios and percentages. some went so far as to say a spark plug in the tank would fail to cause an explosion!!!
Maybe myth busters or how stuff works could go nuts and try it. Pictures needed.
Oh the carnage.

[SGT_MERC]

I just finished putting new pumps in mine. I put weather proof spade connectors on the three wires going to the top side of the tank. This way I can easily disconnect them the next time I have to take the fuel hat out.

[Curless]

when you left them in the car you had to take the cover up to the 8 pin connector apart. did you just tape it back together.
or did you cut any wires?


I NEVER cut wires on any car we work on here at my shop. We take the connector apart and re pin them if we need to remove or add anything to the wiring. Modern cars have very picky sensors and we are not going to add any resistance by cutting or splicing wires.

[Marauderjack]

I studied the wires in gas tank thing on the internet. Its some kind of mad science involving ratios and percentages. some went so far as to say a spark plug in the tank would fail to cause an explosion!!!
Maybe myth busters or how stuff works could go nuts and try it. Pictures needed.
Oh the carnage.

No oxygen in the tank thus gasoline cannot and will not ignite!!:shake:

The pump motor actually runs while submerged and full of gasoline......a little TCW-3 oil in the gas will make your pump last a looooong time...not to mention the upper cylinder stuff in the engine!!:beer:

I have almost 170,000 miles on my WalBro fuel pump...hasn't missed a beat!!:bows:

[vegasmarauder]

After doing about 8 pumps on MM's, MGM's and CV's, I have found this is the easiest and fastest way to change the pump assembly.
Shut off the air suspension switch in the trunk and raise the car until the rear wheels are hanging at the bottom of their travel.
Remove the bolt holding the right rear exhaust hanger to the frame. This will allow the pipe to move outboard a lot easier.
Loosen the driver's side tank strap nut until it reaches the end of the travel, but do not remove it.
Remove the passenger side strap nut with a long extension and socket. The tank will drop down about 3-4 inches on the passenger side and allow access to the connector and the metal retaining clips on the tank pressure sensor wires.
If you have big hands like me, I use a long bladed screwdriver to depress the retaining clip on the connector plug and pull the wires off. Look at the orientation of the connector on the new pump assembly to see the location of the retaining clip, but I think its on the top of the connector. I conned the wife into reaching in with her small hands and undoing it, but it was on her car.
The wires are clipped on the outboard passenger side of the tank and on top of the passenger side of the tank at the mating seam. A long flat screwdriver will pop the top clip off. To put the clip on, i position it in place and use the long screwdriver to push the clip onto the top tank seam.
Remove the pump bolts and fish the pump assembly out. use your fingers to move the fuel guage sending unit float arm so it is next to the pick up tube and then rotate 90 degress to get the float out. The pump goes up and over the axle housing and comes out in front of the passenger side of the axle. You have to pull the exhaust outboard to remove the pump from the tank.
Install is the reverse. Use a block of wood under the tank on a floor jack to lift the tank back in place being careful not to dent the tank.
Start the passenger strap nut back on and as you tighten them up it will pull the tank back into place.

The hardest part for me is the tank pressure connector.

[JohnE]

I have never had a problem removing and replacing the fuel pickup assembly. Never moved pipes or cut wires either. There is enough room to do this in place. Only trick is starting with a low enough level of fuel.

The connector is a little tough to reach, but I have always been able to do this on multiple Panthers, including my Marauder. The fuel pickup assembly rotates and clears all of the parts without removing anything else. Treat it as a puzzle if you have the aptitude for it.

[marshall smith]

try again tomorrow hopefully i'll find my way.
let ya know how it works
aloha

[marshall smith]

well getting the pump in and out was easy but i'm still having trouble with the sensor on the top. i have all the old and new wires in their now. if i can't get it out or reroute the wires. the last step will be to cut and reattach the wires. not my first choice