VR-speed.com<\/a>. The new unit came with a handy installation kit that contained the correct wiring harness, O ring, cap and strainer. I had to reuse the spacer from my old pump.<\/p>\nI began by disconnecting the battery cable. I did not want any sparks while opening the fuel tank inside the car. I removed the spare tire and then the paper cover on the left side. This uncovered a panel held in place by two Phillips screws. The screws came out easy enough but the glue that held the cover had a tenacious grip. I ended up bending the cover from all the prying needing to separate the glue. With he cover off, I slipped the wire through the hole and set it aside for re straightening. <\/p>\n
Next I attempted to disconnect the fuel line from the fitting. I used the proper 14mm and 19mm line breaking wrenches but I was not able to get the line loose. I only succeeded in rounding off part of the hex on the metal line.<\/p>\n
I found a handy guide on VFAQ.com and learned that I could take the line loose under the car. This connection came loose easily.<\/p>\n
I was now worried about the six little 8mm nuts that hold the plate on top of the tank. However these came loose easily with some soaking in PB Blaster. I worked the nuts back and forth whenever I hit resistance and did not break any studs.<\/p>\n
The gasket was stuck pretty good and I had to be very careful to work it over the studs as I separated the plate from the tank. Once the gasket was separated, I was able to twist and turn the pump holder to get it out of the hole with the hose still attached. My compliments to the de-signer of the access hole. It was just big enough to get the pump holder out.<\/p>\n
With the holder out, I took the whole assembly to the shop. The Philips screw that holds the bottom pump clip refused to budge at first. I resorted to using vise grips to break it loose before I damaged the Phillips part. The negative wire had a Phillips screw that came out easily. The positive wire was held in place by a 7mm nut. I was surprised to learn I actually do own a 7mm wrench and took the nut off to free the wire.<\/p>\n
I had to tug some to get the pump out of the tube but with some twisting, it came free. I then clamped the assembly in the vise to try to free the rubber line. I succeeded in rounding off the fitting more but not in getting it loose. I even tried heating it but it did not come loose.<\/p>\n
The pump from VR Speed came with a very nice installation kit. The wiring harness was terminated with the proper ring connectors and the wires were the right length. I simply reused the spacer from my old pump and the new O ring and cap from the kit. I slipped the foam sleeve over the pump. I had a little trouble getting the filter to snap in place. I eventually used two small screwdrivers to press the tiny metal ring on the pin.<\/p>\n
Once the pump was assembled on the holder, I replaced the bottom bracket. I then connected the two wires to the terminals on the holder. I did not use the included zip tie because it looked like it would put a side load on the pump and not add any benefit.<\/p>\n
Later when I installed the pump in the tank however, I managed to hang the red wire on one of the studs and pinch it. I later used the zip tie to hold the wire out of the way during installation.<\/p>\n
After a few tries, I eventually got the pump holder back in the tank with the gasket in the proper place. I snugged down the six little nuts and then crawled under the car and reconnected the line.
\nI used my bypass switch to test the pump. It made a loud whir the quieted down once the line filled with fuel. I was getting ready to button it all up when I noticed that the hose was leaking near the fitting. I had obviously damaged it when I heated it trying to get it off.<\/p>\n
I crawled under the car and disconnected the line. I then removed the pump holder once again being extra careful with the gasket. I took the assembly back to the shop and tried again to re-move the hose. Now it had to come off. No amount of torque would free the fitting.<\/p>\n
I finally resorted to heating the fitting until the hose melted and then had to continue until it was cherry red before it would separate. Even then, I had to reheat it once to get it all the way off.<\/p>\n
I then used a triangle file to clean up the threads on the fitting and was able to get the fitting to screw on and off easily. I then began searching for another hose.<\/p>\n
One of my friends was in the pull a part yard but he was not able to find an AWD. We were not sure if a FWD hose was the same but he could not find one easily accessible to measure.<\/p>\n
Another friend stopped by O\u2019reilies and brought over some fuel hose. However the hose she brought did not have a pressure rating so I was not comfortable using it for the high pressure of the EFI system. When we went to return the hose, I noticed they made hydraulic lines. I asked them if they could make me up a new hose. They said \u201cSure\u201d and I waited for a new hose to be made. I was really surprised they had the right fittings in stock. Well, that turned out to be too good to be true.<\/p>\n
When I got home, I found that the fittings he had used were English; not the 14mm x 1.5 needed for the Talon. Oh and no refunds for the custom made part.<\/p>\n
My last ditch effort was to try to reuse the old hose. I cut off as little of the burned end as possible to keep the hose near the original length. I then cut the ferrule off the original fitting. I slid the hose over the fitting and used a worm drive clamp to secure it. I then mounted the holder in the tank again and then attached the shortened fuel line. The shorter hose was just long enough to work.<\/p>\n
When I tested the pump this time, there were no leaks. I then put all the panels and spare tire back in place.<\/p>\n
When I stared the car, it stumbled for a few minutes before settling down to a smooth idle. There was a severe stumble just of idle but that went away as it warmed up. I seem to remember that the engine always runs a bit rough when ever the battery cable is disconnected and the ECU resets.<\/p>\n
I took it for a short drive and was very happy with the engine\u2019s return to perkiness. It had felt rather week on the dying pump. Later, I took it for a longer drive and as the computer relearned things, it got smoother and more powerful. It handled 12 psi of boost easily.<\/p>\n
I am very happy to have my Talon running again.<\/p>\n","protected":false},"excerpt":{"rendered":"
1G DSM AWD Fuel pump replacement The fuel pump in my 1991 Eagle Talon AWD failed recently. I got a new Walboro from VR-speed.com. The new unit came with a handy installation kit that contained the correct wiring harness, O ring, cap and strainer. I had to reuse the spacer from my old pump. I … <\/p>\n
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