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Aw11 fuel pump replacement, Help needed please.

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2lateforPplate
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2016/01/02 18:21:43 (permalink)
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Aw11 fuel pump replacement, Help needed please.

Hello,
I have 14amps draw on a fuel pump that makes no noise and does not shift fuel. 4 amps is normal so I think the pump has seized. I tried spiking it fwd/rev with 24VDC but that didn't budge it. So it's time to drop the tank and replace the pump and screen. Car is an 87 N/A with AC. Job is being done on stands. I think I'm near the halfway point of this procedure but can't go further.
 
Hoses successfully disconnected:
1 x Fuel filler hose. (50mm)
1 x Fuel filler breather hose. (textile on outside)
1 x EFI supply line. (Tank hard line 1, removed at filter banjo)
1 x EFI return line. (Tank hard line 2)
1 x Evaporative line. (Tank hard line 3, goes to carbon canister port 2)
2 x Evaporative lines. (Goes to condensation tower)
(7 in total)
 
Electrical connectors, underbody covers, cross members and both tank straps are released. The front of the tank is free to move up/dn, the rear can wiggle around 20mm but it is not free. I am trying to slide it forward to clear the AC pipes but It won't budge.
 
Now some questions:
1. Is BGB FSM page FI-71&72 and EC-6&7 the only official guide to dropping the tank?
2. Does the Haynes or Chilton manuals handle the task in any more detail?
3. Is there anything on youtube or elsewhere that will help (other than "AW11 Mr2 Fuel Pump Removal" by dickslaptheclown, "MR2 drop your fuel tank" by graysgarage)
4. Is there some mechanical connection or snag point I've missed?
 
I have used a bit of brute force, a pipe inspection camera and lots of contortion but just cant work out whats wrong. Next step looks like lots more brute force and then replace what was stuck and is now broke (not my favourite option)
 
Any help would be most appreciated.
Regards,
SteveB
 
 
 
 
 
 
 
#1


3 Replies Related Threads
    skipsmr2aw11
    MR2 Enthusiast
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    Re: Aw11 fuel pump replacement, Help needed please. 2016/01/03 01:01:45 (permalink)
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    Hello,       I have removed three tanks over the last 5 years.Problem is,now I cant remember how it was done.
                        I do remember it being a very tight fit.I did use a leverage bar(jack handle)and put it between the tank and floor of car,then gently(with swear words)levered-jiggled and prised it out of there.
                 A couple things to remember;   have a jack/stands or something under the tank.When it does release,you do not want to be stuck under it.Especially if you still have fuel in it.
                                                               Have you pulled out the centre console inside the car and unplugged the wires that go to tank(fuel guage,I think).
                                                               The straps that hold tank in can be removed completely.One side is bolted and the other side is a pin/split pin thing.
                                                               Have a can of flyspray with you.You may upset a family of spiders.
                                                               Give me a yell if you break anything.I probably have a replacement here somewhere.
                                            Thank you...skip.
    #2
    2lateforPplate
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    Re: Aw11 fuel pump replacement, Help needed please. 2016/01/03 07:38:07 (permalink)
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    Skip,
    My car was left outside in country SA as a non runner for quite a while. It's had three sessions with a power cleaner and surface spray so I hope I have got all the spiders. Tank weight is now fine as I have the drain plugged version. All wires and hoses are free, including the filler tube, so it should have no resistance. (Which is why I think I have missed something)
     
    3 Tanks? Speechless......
    1. Did you order new gaskets or use a sealant on the old ones?
    SteveB
     
    #3

    skipsmr2aw11
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    Re: Aw11 fuel pump replacement, Help needed please. 2016/01/03 12:48:49 (permalink)
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    The 3 tanks are from cars that were wrecked out....one went sideways into a pole - one had terminal cancer - and one went 50 feet under water.
        Tanks were never re-fitted (not by me,anyway).The only seal/gasket needed is around the fuel pump,where it goes into tank.That should come with a new pump. 
         Another vague memory has surfaced; the tanks have a lip around the edge(where they are joined).I seem to recall that it gets caught on the metal heater/radiator lines.I think that was my major problem.It may be yours too. 
         From memory,the brake and fuel lines are on passenger side and the rad/heater lines are on drivers side.The air con lines are mixed in there somewhere,as well.
         One other note; I did have the brakes/handbrake removed prior to removing tank(I was wrecking car out)so that may have made a difference.Just check that the handbrake cables are not in your way.
           Hope some of that helps.
     
                                    Thank you...skip.
         
    #4
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