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Registered
Join Date: Jun 2004
Location: Rio Rancho, New Mexico
Posts: 1,325
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Replacing my Carrera fuel pump
As part of my preventive maintenance, I replaced the fuel pump in my 170,000 mile '85 Carrera.
No problems with the pump I just didn't want to get caught 100 miles from home with a fuel pump failure. I figured just over 20 years service deserved a new pump. This is a job best done with a lift. Working on the garage floor even with the car up on car stands doesn't leave much room to work. After removing the pan under the steering rack, the pump is just in front of the front cross bar. With the battery disconnected, I pinched the flexible fuel line from tank closed with a vise grip. Not too tight, just enough to close off the fuel flow once it is disconnected. The pump is held in place with a hose clamp around the body of the pump. The clamp is bolted to the cross frame. Loosened the clamp. The electrical terminals are slightly different sizes since one is positive and the other is ground. I use my small 7mm & 8mm wrenches to remove. The Positive terminal is a red wire, the negative a brown wire. After removing the wires, I used a 17mm and 19mm wrench to remove the banjo fitting from the output side of the pump. An ounce or so of fuel drips out. I used a pan half filled with dirt to collect the dripping fuel. At the point with everything loose it's time to loosen the input clamp from the fuel tank. More fuel will drip out. I slipped the old fuel pump off the fitting and quickly slipped the new pump into the hose to keep fuel drippage to a minimum. Even with the fuel line clamped with visegrips it dripped out a few ounces into the dirt filled catch pan. This part is much easier on a lift, safer too. Once the new pump is in place, I installed the electrical terminals noting carefully which is positive and negative. Install the banjo fitting with two new copper sealing washers on each side. These don't come with the new pump. At over $200 they should be in the box. Once the banjo fitting is snugged up, time to tighten the input hose clamp. It was left loose to rotate the pump while installing wires. Tighten the clamp around the pump body. Not too tight just snug. Remove the vise grip from the input hose. Recheck that everything is tight. At this point I reinstalled the ground to the battery, started the car and carefully checked for leaks with my light. No leaks. One last tug on the lines and pump, yep it's all tight. Put the pan back in place. This job is easier and safer with the car up on a lift. Great care must be taken to collect dripping fuel and to keep the fuel drippage to a minimum. You just don't want to risk a fire. This can be dangerous if you are not careful. It's a one hour job on a lift, Took me 2 hours on the ground. Probably smarter to pay the $100 to have it done if you don't have a lift. With a new fuel pump, new crank sensors and a new DME relay, I feel less likely to be stranded in the middle of nowhere.
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DOUG '76 911S 2.7, webers, solex cams, JE pistons, '74 exhaust, 23 & 28 torsion bars, 930 calipers & rotors, Hoosiers on 8's & 9's. '85 911 Carrera, stock, just painted, Orient Red Last edited by 2.7RACER; 03-07-2008 at 11:09 AM.. |
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