Question about fuel pump install

[aleccolin]

92 GSX. Attempt at Walbro installation. Didn't get far.

Removed access cover to find that the top plate, bolts, and fittings are all pretty badly rusted from road salt, like many other things on the car and undercarriage. The fuel fitting looks workable - being of better steel - but the nuts and studs holding down the pump assembly top plate are bad, the first one shears off clean without much torque at all. A second started to feel iffy, so I didn't go any further.

If I have to break all of the studs to get the pump assembly out to install my Walbro, what then do I do to secure it once again? Are the studs screwed into the tank (doubtful), or pressed in during manufacture (more likely)?

Additionally, how can I relieve the fuel system pressure without being able to start the vehicle as prescribed in the repair manual. If I just pull a vacuum on the pressure regulator with a hand unit will that be enough to bleed down the pressure or will having the vehicle sit unused for a couple months be sufficient to bleed any residual pressure?

Thanks to anyone who bothered to read all this and may have some insight.

 

[xcelr8n]

it seems like anyone who tackles the fuel pump for the first time on a 1g needs to buy another sending unit, since they bust there old one.
I *think* that the studs come from the tank and go through the sending unit, you DONT want to snap all these off, or i think you need to replace the tank.
thirdly, what I did to get it off, was soak the studs in oil for a bit, and bang on a 9/32" socket and successfully got 4 of the 6 off, while snapping 2 clear off.
unfortunately i couldnt get my fitting loose, so i hacked it off, got a new sending unit and had to run a new line under the car.
good luck

 

[spendone]

I actually did everything with no problems my first try. I just made sure I soaked everythign in PB Blaster and Liquid Wrench.

 

[Sk8er07999]

I did it with some wd-40. Only broke one I think. Good luck

 

[aleccolin]

Yeah, I soaked those bad boys in PB, I may try another stud and see what happens, but I'm definitely not up to replacing the tank right now. What a PITA. Think I'll be okay with my small 16G, fuel pump rewire, and an S-AFC? I'll probably not run more than 18 lbs of boost.

 

[BluemeanieTSi]

fuel cell :laugh:

 

[kalla]

I soaked everything down in liquid wrench and everything came off really easy (including the fuel line fitting).

 

[4geze63]

if you think changing the pump on a awd is hard try a fwd.

 

[aleccolin]

Yeah I know, usually the AWD is quick and simple...damn road salt. Everything on the undercarriage is rusted. When removing the stock exhaust I think every single bolt broke, which in a way actually sped things up. Oh well, I think I'll just install an inline Walbro 190 and just leave the stock pump to feed the inline, should get pretty good flow and pressure out of that setup.

 

[jab-619]

I actually did everything with no problems my first try. I just made sure I soaked everythign in PB Blaster and Liquid Wrench.

Me 2, that stuff is the $h!t.! Buy some, spray some, let sit and it should come right off.

 

[aleccolin]

Me 2, that stuff is the $h!t.! Buy some, spray some, let sit and it should come right off.

Yeah I'm well aware of PBB's value, I've used probably 6 or 7 of the stuff on many different cars over the past 8 years, some things, like the thin 5 or 6 mm studs holding down the pump assembly top plate, are unfortunately damaged beyond repair and no penetrating lubricant will save it. Time for plan B.