What’s up guys.
Well I think this should be the same for all 240’s made from 1989-1993. Im not sure about S14’s.
For sure this is how to do it for all 91-93’s. Make sure you’ve done all the trouble shooting before assuming it’s the pump. Put a test light to it with ignition on and if it lights, then it’s not a relay problem, and ifere is no noise coming from the pump then you can be pretty sure it is not working.
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Open the gas tank and unscrew the gas cap to release the air preasure.
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Under the hood, by the battery, you will see the fuse box containing the fuel pump fuse. Pull the fuse.
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Start the car untill the engine stops to get all the fuel out of the lines. You may want to start it up a couple of more times to be sure all the fuel is out of the lines. Then put the fuse back.
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Pull the carpet up in the trunk on the right side.
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You will then see a cover plate with an arrow pointing to the front of the car, held by two (2) screws, and an access panel, held by four (4) screws, with wires leading across and down towards the tank.
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Take the two (2) screws off of the cover plate and to reveal the fuel pump wire harness and un-clip it. There is now NO power and your safe to work.
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Now remove the four (4) screws holding on the access panel. Underneath you’ll see the fuel sending unit cover held on by six (6) bolts and two (2) fuel lines attached to it as well held by spring clamps.
Start by using a pair of plyers and slide the clamps back so you can detach the lines from the unit. Remember to slide them back far enough so the lines will come off but, not to far that you can’t easily grab them when it comes time to put the unit back in.
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Then remove the six (6) bolts and take the entire unit out of the tank. The trunk access panel will still be attached so don’t worry. Try to shake off as much gas as you can and put a rag under it and carry it over to a table to work on.
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I was using a pump made by Mechanic M (blue and yellow box) so the rest applies to that make but, it may still be the same for other pumps too. You will see a postive and negative wire on the old pump. Clip those wires in the middle. Then clip the Zap Strap holding the pump to the actual unit.
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There will be a piece of fuel hose attached to the pump in the center. Using plyers, slide the spring clamp up and pull the hose off the pump. There may also be a breather tube on the pump. Remove that too!
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The pump should now be free and clear. Take your new pump and new filter bag and attach it to the new pump at the bottom by pushing it on. Then attach the new ruber mount to bottom of the pump. You can also use the sponge sleve and slide it over the pump now if you wish. I did’nt bother though.
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Now using the wires provided with pump, attach the positive and negative wire, respectabely, back together. Then attach them to the correct terminals on your new pump. You then can attach the fuel hose back on to the center of pump and slide the spring clamp back in place. With my new pump the breather tube was not needed but it may be with yours. Make sure to check that.
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Using the new Zap Straps, secure the new pump on to the sending unit. Your now ready to put it back in the tank. Just bolt and screw everything back in place as they where. Don’t forget to attach the two (2) fuel lines too. Now clip the harness back together and your ready to try and start the car.
First turn the key to the “ON” position and listen to hear the pump. It will sound like a humming sound. If you hear that you know you installed right. Start the car. It may take a couple of try’s but if everything is done right your car will come to life. That’s it, your done!
Well Im not sure this is a repeat post, I hope not. I just thought I’d give this information for those DYI kind of people. You don’t need to be a mechanic to do this. Just take your time, look at the old pump and the way it’s assembled and make yours look the same.
Take care everyone.
Easy