Replacing Fuel Pump

Does anyone have any tricks to installing a new fuel pump...more specifically, how to get it installed with the o-ring seal? Been fussing with it for a couple of hrs now, cant get the unit and seal installed. Tank is drained. Tried oiling up the seal, rubber mallet, etc. but not banging too hard. Anyone try microwaving the seal to get it more flexible..??

'99 Sub

thanks.

Does anyone have any tricks to installing a new fuel pump...more specifically, how to get it installed with the o-ring seal? Been fussing with it for a couple of hrs now, cant get the unit and seal installed. Tank is drained. Tried oiling up the seal, rubber mallet, etc. but not banging too hard. Anyone try microwaving the seal to get it more flexible..??

'99 Sub

thanks.

if the seal is too hard replace....any cracks replace.

get a pan of boiling water and give it a bath this should make it more flexable ..if not get new..

Yep that did it...I think...it cooled down a bit by the time I actually got it in. For some reason it was just a tight fit, but the combo of bath and oil worked.

Thanks to all who looked and who posted their questions and responses in years past. Great source of info. Probably would have had to take it to the shop otherwise...~$450

Just have to work it, press evenly, rag on top of unit, no rubber hammer required. All back together, working, fuel gauge is accurate, etc.

So..couple of opinions...1. drain tank all the way(vs dropping it with 1/2 tank or less)...I had about 8 gals when removing, was a pain, but not when installing. 2. The plastic fuel line decouplers worked for me, didnt have to buy metal ones. I had more success working from the left side of the tank/car decoupling the fuel lines, even though there was less space to work with (as the tank was drooping on the right) 3. Recommend (as previously mentioned) removing the 3 gas cap screws, allows the fill hose to travel to where you can get to the hose clamp on the tank. 4. If I had more time I would have built an adapter for the floor jack.

this gas tank is 34 gallons 1/2 tank would be 17 gal X 8 lbs =136 lbs....thats too heavy to handle...1/4 tank is the most...70lbs..


jack up the burb and siphon out to another vehicle....

i used a 2x6 block and a floor jack centered on the tank worked great.didn't like the plastic tube that goes inside the filler neck p.i.t.a.