RRE  2G Denso Fuel Pump Instructions 

 

Remove and Install Pump Assy

Remove the gas cap to let any pressure out of the tank. 

Remove the rear seat bottom. There are two tabs at the front of the seat. Pull them towards the front of the car and lift up on the seat bottom. 

There is a cover on the passenger side of the floor under the seat. Remove the Philips screws and also the Phillips screw that holds the plastic wire harness cover. Lift up on the cover. It has some sealant on it that will still hold it down some.

Jack the car up to gain access under the passenger side rear corner. 
2gfuelpumpinstall01.jpg (30384 bytes) The fuel line at the top of the tank needs to spin when it is removed. The only way to do this is to disconnect the fuel line under the car.

There is a junction in the high pressure fuel line that needs to be unscrewed. 
2gfuelpumpinstall02.jpg (28948 bytes) Put a drain bucket under the fitting junction to catch any spilling fuel.
Now break loose the upper fitting. There are also two smaller vent hoses that need to be removed from the top of the fuel pump assembly.

 

2G FWD
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2G AWD

The AWD pump is a little more complicated. The fuel level sender is part of the fuel pump assembly. Before removing the fuel pump, make some markings on the fuel pump and tank so that you can get the assembly rotated back in the exact same spot.

To remove the pump assembly, use a hammer and large screwdriver to unscrew the large black retaining ring. 
2g-gsxfuelpumpinstall-wireclearance.jpg (234110 bytes) Wires connector cut off 
2g-gsxfuelpumpinstall-crimpingwires.jpg (199116 bytes) Crimping on new eye connectors. 

Blue is positive, lack is Negative. The nuts are 7mm and 8mm.
2g-gsxfuelpumpinstall-orings.jpg (253202 bytes) O-ring and cap swapped over from stock fuel pump. Be careful with the white plastic cap. Gently and slowly pry it off the old pump. 
2g-gsxfuelpumpinstall-bottom.jpg (213489 bytes) Bottom of pump, clocking of the bracket shown.
2g-gsxfuelpumpinstall-wireclewarance2.jpg (189336 bytes) Slot the sides of the white plastic connector. This allows the wires to go out the side more to clear the top edge of the fuel pump.
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2g-gsxfuelpumpinstall-mainseal.jpg (178518 bytes) When re-installing the pump assy, be careful that the rubber seal is in the groove properly.
A little soap for lubricant on the seal will help with installing the seal. Check that the rotation of the pump is the same as when before you removed it. If you get it wrong, the fuel level gauge will be slightly off. 

 

Contact Road///Race Engineering
13022 La Dana Ct, Santa Fe Springs, Ca. 90670
Phone (562) 777-1522   Fax (562) 777-1562

Last Updated 1/04mw