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Old 04-19-2010, 06:32 PM   #1 (permalink)
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Default GT500 Fuel Pump


3 hours for install, not too hard with basic hand tools, nothing special needed. Ford has a pretty good write up on this but they dont cover the small details and a few tricks to make it go easy.

Good ideal to do this with a empty tank unless you like the smell of gas. I had less than a inch of fuel accross the bottom of the tank when my gauge was on empty.

You will notice the BAP in the trunk, I installed this prior to the new pumps and removed it when the new pumps went in, I should not need it at this point.

Our fuel tanks are made up of 2 sections because our driveshaft and exhaust running thru the tank, so you have 2 pumps, we are only dealing with the driver side pump.

Start with jacking up the front passenger side of the car. If you have to use a ramp like i do,you want to make sure you do this first before pulling the fuel pump relay.


With the car jacked up, pull relay 21 under the hood, this should kill the fuel pump. Crank the engine over to make sure,the car should not start. If it does start, then it should die quickly and not restart.


Take out the rear seat by looking at the front bottom of the seat and just pushing in the plastic clips, it comes out very easy, There is one clip on each side.


Strip down the rear, pull the panel out and the spare tire.


Heres what the fuel pump cover looks like soon as you pull the seat out, there is one on the driver and one on the passenger side, we are only dealing with the driver side pump. This cover just pulls off.


Remove the lock ring with a screwdriver and hammer, my picture shows the fuel line already disconnected but its better to wait on the fuel line until the lock ring is off. New pumps come with a new gasket and lock ring, so you can abuse the old lock ring as much as you wish when trying to remove it, it does come off with small little at a time so no need to whale on it real hard.


This picture shows how to release the fuel line by just pinching the sides together and it just pops off (* do not remove the fuel line until you actually have the lock ring removed first OR it will cause gas to splash up while you are beating the lock ring off * )


When the lock ring is removed the pump will pop up, the assembly is spring loaded so it may pop up about 1 inch.


You will have to work it out, the hoses do get hung up so just work it side to side. Looking at this picture you can see the passenger side fuel line connected to the main fuel pump.


To remove this hose, just push down on the green tab and it will pop right off.


Pulled out.


Inside the tank you can see the passenger side line.


Side by side,old and new.


Side by side again.


Looking inside the tank you can see a tray that the pump sits in, when you install the new pump you have to make sure the float is outside that tray and facing the passenger side.


Getting the new pump in is not easy, it takes alot of wiggeling and squeezing but it will go if you are pateint. Start with the pump on its side and the float going staight into the tank. You dont have to worry about the passnger side fuel line too much, it will be in the right spot when you get the pump in and you will be able to grab it. Once you get the float in, twist the whole pump towards the passenger side, making sure the float will clear the tray inside the tank. You will have to squeeze the hoses from side to side to get the pump down in the hole.
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Re: GT500 Fuel Pump
Old 04-19-2010, 06:33 PM   #2 (permalink)
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With the pump down in the hole, the passenger side hook up will be at about 2 "O" clock.


Just push the passenger side hose on until it clicks.


Pulled the tire off and pulled off 6 push clips to get the inner fender plastics pulled down.


Here you can see what is exposed with the inner fenders pulled down.


Inner fender exposed.


Here is the power wire coming thru the firewall. the power wire already has a fuse holder attached to it and its way to big to get thru the grommet so i just cut the fuse holder off and soldered it back on once the wire was thru the grommet.


All zip tied and taped up.


There is a small hole just blow the fuse box that you can bring your power wire up thru. Zip tie it to the factory harness and connect it to the power side of the fuse box.


Only thing left is to hook up the new harness to the new pump. unfortunatly its not that simple, you have to pull the fuel gauge sender wires (light blue-yellow stripe and light green violet stripe) out of the old harness and slide them into the new harness. You will need a small tipped screwdriver to do this. The blue piece of plastic has to come out first.


You can use the small screwdriver to push the blue piece out from one of the small openings on the side.


With the blue plastic out of the way, use the tip of the screwdriver to pry the plastic clip that holds the wire connector in place. Remove the black plastic clip from the back of the plug and blue rubber piece, the light blue-yellow stripe and light green violet stripe wire should come right out.


Should look like this.


Now put the 2 wires into the new harness in the reverse order. Should look like this.


And this.


Next you have to cut out a new spot for the new harness on the fuel pump cover,i used a razor blade. 1-1/2 inch hole, about 1 inch from the existing hole.
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Re: GT500 Fuel Pump
Old 04-19-2010, 06:34 PM   #3 (permalink)
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Pull your wires thru.


Reinstall the cover.

Thats it, reinstall your fuel pump relay and crank it up, check your fuel gauge to make sure the wires are OK and you get a reading.


Thanks to "one eyed willy" from mustangforums.com
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Re: GT500 Fuel Pump
Old 04-19-2010, 10:11 PM   #4 (permalink)
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Dude, I did mine today too. We couldnt figure out the wiring part from the pump and the blue/green/yellow wires or whatever.

We didnt even jack the car up or anything. There were moments though where we were kinda stuck. But everything was good.

You didnt do it by yourself did you?
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Re: GT500 Fuel Pump
Old 04-19-2010, 11:04 PM   #5 (permalink)
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Default Re: GT500 Fuel Pump

I didn't write that up. I just copied it from mustangforums and posted it here haha. I'm still running a BAP
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Re: GT500 Fuel Pump
Old 04-20-2010, 06:12 AM   #6 (permalink)
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Default Re: GT500 Fuel Pump

Oh...well then if you ever do it good luck lol.

Fords wires are different than the directions so that was a problem.
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Re: GT500 Fuel Pump
Old 04-20-2010, 07:56 AM   #7 (permalink)
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now think of the guy 5 or 10 years down the road that comes across this and looks at how clean everything is under the trunk liner. i pulled the carpet back in my 93 camry not long ago. talk about dust bunnys, WOW! i saw some wires and i couldn't make out the different colors.
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Re: GT500 Fuel Pump
Old 04-20-2010, 10:15 AM   #8 (permalink)
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You should see what under my back seat looks like, holy crap. Shit everywhere
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