ST205 replace fuel pump
HOW TO - REPLACE THE FUEL PUMP ON AN ST205
Submitted by - Gary
** This article has pictures from the ST205, but the procedure is similar for all the GT4s **
Disclaimer
This article is intended as a helpful guide and shows how I replaced the fuel pump. If you are in any doubt, or not qualified, do not undertake this maintenance, consult a qualified mechanic. The fuel pump is an important vehicle component, failure to change this in accordance with the relevant manufacturers and/or procedures and/or instructions can lead to severe damage or injury. The author or the GT4 Drivers Club can not be held responsible for any loss or damage resulting from use of this article.
Safety
When working on a car always use the appropriate safety equipment, chock the wheels to prevent the vehicle from moving. When working underneath a raised vehicle always use axle stands.
Special Precautions
Disconnect battery and ensure NO naked flames or sources of ignition are present close by. It is wise to have a decent sized foam or dry powder fire extinguisher on hand as well.
Procedure
| Inside the boot, remove the metal access panel and white plastic conduit cover and disconnect the two multi plugs | |
| <a href="06.jpg"><img border="0" src="thumbs/06_small.jpg"></a> | Remove fuel filler / inner arch guard |
| <a href="01.jpg"><img border="0" src="thumbs/01_small.jpg"></a> | ... then remove the fuel tank cover. 6 bolts and one panel clip IIRC |
| <a href="07.jpg"><img border="0" src="thumbs/07_small.jpg"></a> | The removed cover |
| <a href="08.jpg"><img border="0" src="thumbs/08_small.jpg"></a> | Which allows full access to the tank |
| <a href="02.jpg"><img border="0" src="thumbs/02_small.jpg"></a> | Remove the 4 screws holding the filler flap in place |
| <a href="03.jpg"><img border="0" src="thumbs/03_small.jpg"></a> | .... and simply carefully pull the assembly to one side |
| <a href="04.jpg"><img border="0" src="thumbs/04_small.jpg"></a> | Filler tube is not secured anywhere else so no more clamps etc to worry about there. |
| <a href="05.jpg"><img border="0" src="thumbs/05_small.jpg"></a> | Next, remove hose clamps on the return and breather pipes and remove hoses (have a container ready to catch and fuel which may leak out)... |
| <a href="10.jpg"><img border="0" src="thumbs/10_small.jpg"></a> | You can then undo the fuel feed pipe at the union shown below |
| <a href="09.jpg"><img border="0" src="thumbs/09_small.jpg"></a> | With something below the tank to take the weight when it's freed, undo the nuts on the two 'straps', holding the tank in place... |
| <a href="11.jpg"><img border="0" src="thumbs/11_small.jpg"></a> | ... and lower the tank down... |
| <a href="12.jpg"><img border="0" src="thumbs/12_small.jpg"></a> | The fuel tank in all its glory... |
| <a href="14.jpg"><img border="0" src="thumbs/14_small.jpg"></a> | ... and the 'hole' left behind... |
| <a href="13.jpg"><img border="0" src="thumbs/13_small.jpg"></a> | Fuel level sender unit is below the panel closest with the fuel pump 'above' |
| <a href="15.jpg"><img border="0" src="thumbs/15_small.jpg"></a> | Clean the area surrounding the panel to ensure debris etc doesn't fall inside the tank and remove the securing bolts... |
| <a href="16.jpg"><img border="0" src="thumbs/16_small.jpg"></a> | The OE fuel pump... |
| <a href="17.jpg"><img border="0" src="thumbs/17_small.jpg"></a> | The replacement pump. A 255 l/hr Walbro high flow pump rated to 500bhp |
| <a href="18.jpg"><img border="0" src="thumbs/18_small.jpg"></a> | The uprated pump in place. I decided to solder and heat shrink the new +ve and -ve wires in place rather than using the supplied crimps.... |
| Fitment is simply the reverse of above |
- Replace brake discs & pads
- Replace springs and shocks
- Replace CV boots
- Under body seal the rear arch
- Fit rear trailing arm PU bushes
- Fit rear ARB PU bushes
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