Rutchard Posted March 8, 2012 Share Posted March 8, 2012 (edited) Installed my DW300 fuel pump today. Would have been a lot easier if I hadn't filled the tank on Monday. I would recommend anyone attempting this install start with much less gas in the tank (1/4 or less). Pull the fuel pump fuse and then crank the car over a few times to release pressure in the fuel system. Then replace the fuse. http://i.imgur.com/HOAFK01.jpg Since I had a full tank, I had to drain out as much fuel as possible. Disconnected the fuel feed line under the hood and attached 6ft of extra hose and ran it into a fuel can. Keyed the car on and off to keep the fuel pump running and filled both of my gas cans. 7.5gal later my fuel gauge was just a hair over 1/2 tank. Service manual says to have less than 2/3 tank, so I figured I was golden. http://i.imgur.com/dbrKQIe.jpg http://i.imgur.com/xd7Z8DS.jpg http://i.imgur.com/BxWFX2s.jpg Disconnect the negative battery terminal. Pulled out the rear seat cushion. No tools needed, just pull up on the front edge and the two fasteners will pop out. Then maneuver the cushion to release the hook in the center, between the seatbelt buckles. The panel on the passenger side is the one for the fuel pump. http://i.imgur.com/8My3oAJ.jpg Remove the 4 screws holding the cover on. Also remove the plastic clip holding the fuel pump power cable. Then push the rubber grommet inside the cover and remove the cover. http://i.imgur.com/8My3oAJ.jpg It was pretty dirty in there, so try to get as much dust and crap out as possible. You don't want all that junk going into your gas tank! http://i.imgur.com/sPp2uBK.jpg Remove the 8 nuts holding the fuel pump assembly into the tank. There is one under one of the fuel lines under a rubber cap. Be sure not to lose that cap! Unplug the wire harness and disconnect the fuel hoses. Half a tank wasn't low enough, fuel went everywhere when I tried to pull out the pump. Make sure you have as little fuel in the tank as possible if attempting this yourself. Also have lots of rags around. I ended up having to bend a bit of sheet metal with pliers in order to remove the bracket on top of the fuel pump. http://i.imgur.com/C9aqrU3.jpg Edited July 11, 2017 by Rutchard Photobucket Died Link to comment Share on other sites More sharing options...
Rutchard Posted March 8, 2012 Author Share Posted March 8, 2012 (edited) Pull out the fuel pump housing and be very careful not to bend/break the fuel level sensor as you remove it. Set the housing someplace somewhat clean and prepare to disassemble. http://i.imgur.com/5lmbxdJ.jpg Unplug the fuel level sensor and the fuel pump wire harnesses. http://i.imgur.com/EyLazlb.jpg Release this tab and pull the housing apart. http://i.imgur.com/AqbG567.jpg http://i.imgur.com/SgkinNX.jpg Unplug the other end of the fuel pump power harness, you might not have enough room to pull the plug, but just get it loose for now. http://i.imgur.com/EqOkf6V.jpg Pry and remove this collar holding the fuel pump in. Be careful not to break the plastic or gouge out the plastic with your screwdriver. Plastic shavings in the pump housing probably wouldn't be good. Lets not find out! http://i.imgur.com/nJfGN8p.jpg http://i.imgur.com/qDg1ykS.jpg http://i.imgur.com/vD6A32T.jpg Now you can pull out the stock pump, it's in there pretty firmly but will come out eventually. http://i.imgur.com/5qyEXyG.jpg Stock pump next to the DW300 http://i.imgur.com/Y9uN2eu.jpg Pull this black rubber piece off of the stock pump and install it on the DW300. http://i.imgur.com/TQPyBce.jpg http://i.imgur.com/XVwOF0J.jpg I also already installed the new fuel filter sock at this point. Now you can insert the DW300 into the pump housing. Plug in the wire harness. http://i.imgur.com/YtbSXf2.jpg And push the pump all the way into the housing. http://i.imgur.com/rzw2Z5c.jpg With the stock black rubber spacer on top, the plastic collar won't fit. http://i.imgur.com/1KwAASk.jpg http://i.imgur.com/f8H9ovc.jpg Without the spacer the collar pops on snugly and the pump stays in place. http://i.imgur.com/vAh64uS.jpg There was a lot of nasty crap inside the fuel housing, so I flushed it out before putting everything back together. http://i.imgur.com/CS878aD.jpg Reinstall everything in reverse order. Don't forget the rubber cap when reinstalling those 8 nuts. Don't install the cover or rear seat yet. Re-connect the battery and key the car to on but do NOT start the car. Repeat this a few times and look around the top of the fuel pump to make sure all the lines you reconnected aren't leaking. If everything looks good start the car and let it idle for a little bit. Check again for leaks and again, if everything looks fine, then you can put the cover back on and reinstall the back seat. Edited July 11, 2017 by Rutchard Photobucket Sucks Link to comment Share on other sites More sharing options...
wrxwhit Posted March 8, 2012 Share Posted March 8, 2012 Well done, very informative. This will make this install much easier for members. Thanks for this useful post! Link to comment Share on other sites More sharing options...
Types4 Posted March 8, 2012 Share Posted March 8, 2012 Great pics of the install. How much louder is the new pump compared with the stock? Link to comment Share on other sites More sharing options...
Blizzard Posted March 8, 2012 Share Posted March 8, 2012 Great write up Rich. Link to comment Share on other sites More sharing options...
Rutchard Posted March 8, 2012 Author Share Posted March 8, 2012 How much louder is the new pump compared with the stock? Not much louder at all, I was pleasantly surprised Link to comment Share on other sites More sharing options...
GravityGear Posted March 8, 2012 Share Posted March 8, 2012 i tried installing the walbro some months back, no go. but the dw looks good. Link to comment Share on other sites More sharing options...
CL21376 Posted March 8, 2012 Share Posted March 8, 2012 Nice writeup Link to comment Share on other sites More sharing options...
Patrickturner Posted March 9, 2012 Share Posted March 9, 2012 Sorry If I am a little slow, but whats the purpose to replace the fuel pump? Was the old one bad? Link to comment Share on other sites More sharing options...
spec.B Dream Posted March 9, 2012 Share Posted March 9, 2012 Excellent write up! The purpose of replacing the fuel pump is to provide more fuel for larger injectors. Link to comment Share on other sites More sharing options...
Rutchard Posted March 9, 2012 Author Share Posted March 9, 2012 The purpose of replacing the fuel pump is to provide more fuel for larger injectors. 1000cc injectors are coming soon, I just need another nice day to get my wideband installed and I'm ready. Link to comment Share on other sites More sharing options...
Blizzard Posted March 9, 2012 Share Posted March 9, 2012 Saw Rich at a local meet last night. I couldn't even hear the pump when it primed, sounds just like stock. Link to comment Share on other sites More sharing options...
DeatschWerks Posted March 12, 2012 Share Posted March 12, 2012 Nice write-up, Rutchard. Good pictures and instructions. ...and you made the correct call on installing it without the lower pump isolator (the rubber bushing/grommet). Link to comment Share on other sites More sharing options...
nadracer Posted March 12, 2012 Share Posted March 12, 2012 I think I already have my answer but would any efficiencies be gained by having a better pump installed on a N/A car? Not that it needs more fuel but maybe better delivery of the required amount. Link to comment Share on other sites More sharing options...
bmx045 Posted March 12, 2012 Share Posted March 12, 2012 I think I already have my answer but would any efficiencies be gained by having a better pump installed on a N/A car? Not that it needs more fuel but maybe better delivery of the required amount. No. Link to comment Share on other sites More sharing options...
nadracer Posted March 13, 2012 Share Posted March 13, 2012 No. word Link to comment Share on other sites More sharing options...
islandborn Posted September 15, 2012 Share Posted September 15, 2012 This will be my guide for next weekend! Thanks ahead of time Rutchard! By the way... got a write up on the ID 1000s? Link to comment Share on other sites More sharing options...
hmmrdwn Posted September 15, 2012 Share Posted September 15, 2012 Nice job. Link to comment Share on other sites More sharing options...
Rutchard Posted September 15, 2012 Author Share Posted September 15, 2012 By the way... got a write up on the ID 1000s? The way I did the injectors was... took the car to a shop and paid them to do it, lol Link to comment Share on other sites More sharing options...
minuccims Posted September 15, 2012 Share Posted September 15, 2012 simple, informative, to the point! Link to comment Share on other sites More sharing options...
islandborn Posted September 15, 2012 Share Posted September 15, 2012 The way I did the injectors was... took the car to a shop and paid them to do it, lol Are they that hard? or you just didn't want to screw with it? Im getting the plugs so I don't have to cut into anything - plug and play. Link to comment Share on other sites More sharing options...
Rutchard Posted September 15, 2012 Author Share Posted September 15, 2012 Mine weren't ID's, but they were plug & play. I honestly didn't feel like messing with it. Was easier to just pay someone who knew what they were doing. Plus they were installed 10ft from the dyno so I didn't have to worry about getting a limp map to drive to the shop on. Innovative said it was a little more difficult than the previous gen because the charge pipe is in the way on the passenger side. Link to comment Share on other sites More sharing options...
islandborn Posted December 29, 2012 Share Posted December 29, 2012 I would like to throw a big thanks to Rutchard. I just put my DW300 in today and followed this awesome writeup. Had my Ipad out scrolling through the pics while I did it step by step. So THANK YOU Rutchard. If we ever meet, I'm buying you a pitcher of whatever beer you want. Link to comment Share on other sites More sharing options...
crashdumbe Posted April 3, 2013 Share Posted April 3, 2013 awesome, thanks! Link to comment Share on other sites More sharing options...
Rutchard Posted April 3, 2013 Author Share Posted April 3, 2013 awesome, thanks! Just FYI, this install is for a 5th gen LGT. Not an 05 LGT... Link to comment Share on other sites More sharing options...
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