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Pelican Technical Article:

Fuel Pump Replacement

Steve Vernon

Time:

2 hours2 hrs

Tab:

$200 to $300

Talent:

**

Tools:

13mm socket, hose clamp, 19mm, 17mm, 8mm, 7mm wrench, Philips and flathead screwdriver, rags, floor jack, jack stands, wheel chocks, safety glasses, torque wrench

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

Fuel pump and fuel pump-sealing O-ring

Hot Tip:

Use all precautions when working around fuel

Performance Gain:

Better running engine

Complementary Modification:

Replace fuel filter

A faulty fuel pump can cause poor engine performance and hard starting problems. When they fail completely, you will be left with an engine that doesn't run at all. While the fuel pumps in the Porsche 944 are not known to be prone to failure, like anything mechanical they will eventually wear out. If your pump has gone bad make sure that it is not some other problem with the fuel system, like a clogged tank or filter causing the pump to fail

The fuel pump is located under the vehicle near the tank on the right side. When replacing, work in a well-ventilated area. Working outdoors is a good choice. Do not use incandescent work lights or power tools. Also, DO NOT smoke. Fuel and fuel vapors are highly combustible.

You will need to safely raise and support the rear of the vehicle. Please see our article on safely raising and supporting your Porsche 944.

Begin by disconnecting the negative cable from the battery (red arrow) and making sure it cannot come in contact with the post while you are working.
Figure 1

Begin by disconnecting the negative cable from the battery (red arrow) and making sure it cannot come in contact with the post while you are working.

If your fuel pump has a cover over it (yellow arrow), you will need to use a 13mm socket and remove the single bolt that holds the hanger in place (red arrow).
Figure 2

If your fuel pump has a cover over it (yellow arrow), you will need to use a 13mm socket and remove the single bolt that holds the hanger in place (red arrow).

The cover is made up of two sections; remove the two Philips head screws (red arrows), and separate the rear section of the cover (yellow arrow).
Figure 3

The cover is made up of two sections; remove the two Philips head screws (red arrows), and separate the rear section of the cover (yellow arrow).

This will give you access to the fuel supply line from the tank.
Figure 4

This will give you access to the fuel supply line from the tank. Use a set of hose clamps and clamp this line off (red arrow).

Disconnect the wiring from the pump (green arrow) to the harness (red arrow).
Figure 5

Disconnect the wiring from the pump (green arrow) to the harness (red arrow).

Use a flathead screwdriver and remove the clamp from the tank line to pump (red arrow).
Figure 6

Use a flathead screwdriver and remove the clamp from the tank line to pump (red arrow). Even though you have clamped the line, there will still be fuel in the line and filter. Be prepared to catch the fuel and dispose of it in accordance with the regulations in your area.

Use a flathead screwdriver and loosen the clamp holding the pump in place to the cover (red arrow).
Figure 7

Use a flathead screwdriver and loosen the clamp holding the pump in place to the cover (red arrow). Slide the pump (yellow arrow) out from the cover and remove the cover.

If your pump does not have the plugs on the wiring connection, you can use a 7mm and 8mm wrench and disconnect the wiring from the pump itself.
Figure 8

If your pump does not have the plugs on the wiring connection, you can use a 7mm and 8mm wrench and disconnect the wiring from the pump itself. The ground uses a 8mm nut (yellow arrow). The positive cable uses a 7mm nut (red arrow); do not mix them up.

There is a banjo bolt holding the fuel out line from the pump to the filter.
Figure 9

There is a banjo bolt holding the fuel out line from the pump to the filter. Use a 19mm wrench to loosen and separate the banjo. There is a smaller 17mm nut used closer to the pump, which you will need to support, as well as a crush washer (yellow arrow) that must be replaced every time you remove the fitting. Make sure that you have a new washer before you start the job. Installation is the reverse of removal. Do not over tighten the clamp holding the pump in place. It can damage the performance of the pump.




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