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Old 10-07-2006, 12:58 PM   #1
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Default Installing a fuel pump into your Second Generation DSM

The install of the fuel pump is straightforward procedure, and can be installed by an above average mechanic.

NOTE!! As with all of our installs and walkthroughs, our guides should be used only as a guide. Use extreme care when working around the gas tank, fumes are highly combustible and can be toxic.

First pop the trunk and leave it open, this will allow the gas fumes to escape while you are working on the car.

We are installing a Denso pump into a 1996 Mitsubishi Eclipse GSX.

We carry many fuel pumps for this application.

We begin by jacking the car up on the rear end, make sure to use jackstands in this install



Push your passenger seat to the furthestmost forward position, and pull the 2 black tabs located under your rear seats. The rear seat should now come straight up and out. Using a Phillips screwdriver, remove the 4 screws holding the metal access panel, and the 1 screw holding the plastic wiring loom guide. Remove the access panel to expose the fuel pump.







Next, get a hammer and a flathead screwdriver, or blunt chisel. You will see that the fuel pump is held into position by a plastic guide ring, shown here.



Using the flathead screwdriver or similar device, place it against the ridges of the ring, and tap gently with the hammer until the ring starts to move



Once the plastic ring is loose, get out of the car and open your gas cap to relieve pressure in your tank.



Then directly under the fuel pump assembly, you will find a hose thats marked red



Use a 19mm and 14mm open ended wrench and undo this line, disconnect it and let it hang. You might want to have some spare rags laying under this spot as gas will spill out.







Unplug the white harness from your fuel pump, and undo the 2 fuel lines from the upper nipples.



OPTIONAL
This next step you may or may not need / want to do. Using a pair of tin snips, we cut away a small triangle section, allowing easier access to the fuel pump assembly and related lines. You may or may not choose to do this, we prefer to, as it makes removing the fuel pump assembly easier.

If you do not choose to do this, go to step "Remove the fuel pump assembly as a whole".



Do your best to make the cut as clean as possible, bend any extra pieces back onto the chassis.



Remove the fuel pump assembly as a whole.



Put the fuel pump on a clean location, preferably a nice piece of cardboard. Make sure not to loose any of the spare c-clips or related parts



With your Phillips screwdriver, undo the screw shown here. This will allow you to undo the entire assembly.



Now pull out your stock pump, take care as to not loose the white plastic ring, the oring beneath it or the plastic guide.



The pump we are installing is NOT a straight plug and play unit. If you have purchased a fuel pump from us, your pump will be plug and play. You will at this step unplug the pump harness and plug your new one in.. skip to step A



Our pump required cutting and reattaching to the new pump, both pumps, new and old are clearly marked + and -. Blue is positive, black is negative. Cut the wires and strip them out nicely



Crimp some connectors onto the wires, and attach them to the new pump. If your pump came with new oring, plastic guide and oring then now is the time to put them back exactly as your stock pump was. If they didnt, then put your stocker pieces onto your new pump.



STEP A
Put the pump back into the assembly, and reassemble the bracket and screw the phillips bolt back into the unit.



Put the entire pump assembly back into the fuel tank, taking care as to not disturb your factory floater. This is the plastic bulb attached to the arm of your assembly, depending on the year / make of your Second Generation, you may or may not have this floater as a part of the pump assembly.

HINT
Put the rubber oring located here in this pic back in place firmly before reinstalling the pump assembly. Improper installation of this rubber ring will cause your car not to start as the tank isnt sealed.



Pressing firmly down on the white oring, start screwing the oring back in. use the hammer and screwdriver trick again to make sure that you have it nice and tight. Reattach all connectors, fuel lines, the 19mm / 14mm junction under the car, the access panel, 5 screws and your rear seat and lower the car. Now is a good time to start the car, watch the area directly under the 19/14mm junction to ensure there are NO LEAKS. You are done! Enjoy your new fuel pump!!

Q : I followed your instructions but I smell a lot of gas, is there a problem?
  • A : Depending on how full your gas tank was at the time of install, some or no fuel may have leaked out onto your tank surface, if this is the case, give it a few days, it should clear up. If this isnt the case, make sure to have the white plastic oring nice and snug, and the pump tightly sealed.
Q : I finished the install and my car took a long time to start, is there something wrong?
  • A : No, you relieved quite a bit of fuel and pressure from the lines, it may take a few times to restore this pressure in your fuel rail and start the car.
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