Fuel Pump Install Help Options

[turbohcar]

Insert random curse words of your choosing here.......

Now, before you say "Vfaq this, PB Blaster that", there are a few things that you should know. I performed this install(removal actually) per the instructions listed on Vfaq.com. Everything was moving according to plan. I had PB Blastered the fuel line off and on all week and was hoping to do something this weekend. I finally got the 14mm line wrench for the fuel line and went to town tonight. First off, the fuel line came off EASY!!! I was surprised. There is rust on top of this fuel tank like you wouldn't believe. Rust that has rusted on top of rust. As I eagerly finish that up I start on the fuel pump assembly bolts (the six little ones) that hold it onto the fuel tank. Here's where the trouble begins. I broke the first one off. Clean off flush with the assembly. Here's where the curse words go. Not only did I break that one off, two others broke as well. The other three came off fine without trouble. So, now I have a problem. I can't put the pump assembly back in with the new pump until I figure out how I'm going to fix this.

I guess my query comes down to this:

Are those studs replaceable or do I need to buy a new fuel tank?

Black92TSiAWD, I know you've got a spare fuel tank, or used to, if you could please look and see if those studs are pressed in or if they are brazed in. I would much appreciate it.

If I do have to go the tank route it's not a big deal, just frustrating. Who would have thought that the hardest part of the whole ordeal would have been those six little bolts?

[turbohcar]

Fuel pump modifications are complete. I simply used three self-tapping, chemical treated (Mitsubishi OE) bolts. I drilled out the holes where the studs are supposed to go by reinserting the fuel pump housing back into the tank and using the top of the housing as a template. I'm also on my way this afternoon for a new rubber housing gasket to go with it. I used a dremel and a sand paper roll to take the remaining rust on the housing. Other than that, it's pretty straight forward. I test fit the bolts in the tank holes and made sure they fit. I am also going to shoot some silicone into the holes where the self-tappers go to make sure that it gets a good seal.

Overall, there was a bit of shavings that made it into the tank but not enough to make a big deal about. Nothing a good tank flush can't fix.

BTW, the kit that came with my Walbro makes installation a breeze. The pump sits straight up and down and uses the same bracket as the stocker. Some slight notching of the spacer was necessary but very easy. I also reused the pump filter retaining clip as it provided a much firmer fit than the one supplied. All I need to do now is to wire up the connections, flush the tank, and put it all back together. The fuel line from tank to filter is up next. I'll keep you all up to date with that too.