GT4 fuel pump replacement/upgrade guide...., Gen 6 (and possible Gen 5) Options

[GT4WRC]

Disconnect battery and ensure no naked flames our sources of ignition are close by. Wise to have a decent sized fire extinguisher on hand too.

Inside the boot, remove the metal access panel and white plastic conduit cover and disconnect the two multiplugs.

Remove fuel filler / inner arch guard..


... then remove the fuel tank cover. 6 bolts and one panel clip IIRC.


The removed cover.


Which allows full access to the tank...


Remove the 4 screws holding the filler flap in place....


.... and simply carefully pull the assembly to one side.


Filler tube is not secured anywhere else so no more clamps etc to worry about there...


Next, remove hose clamps on the return and breather pipes and remove hoses (have a container ready to catch and fuel which may leak out)...


You can then undo the fuel feed pipe at the union shown below...


With something below the tank to take the weight when it's freed, undo the nuts on the two 'straps', holding the tank in place...


... and lower the tank down...


The fuel tank in all its glory...


... and the 'hole' left behind...


Fuel level sender unit is below the panel closest with the fuel pump 'above'.


Clean the area surrounding the panel to ensure debris etc doesn't fall inside the tank and remove the securing bolts...


The OE fuel pump...


The replacement pump. A 255 l/hr Walbro high flow pump rated to 500bhp.


The uprated pump in place. I decided to solder and heatshrink the new +ve and -ve wires in place rather than using the supplied crimps....


Fitment is simply the reverse of above.
Gary

[GT4WRC]

Thanks for your vote of confidence everyone. I guess that not having an ST205 GT-Four anywhere near, you are unable to speak with any authority on this matter No one in their right mind would do all of the above if it was just a simple task of removing four screws and an access panel
FYI, that panel only allows you to remove the fuel level sender unit. The only way to swap the pump is by removing the tank - end of story.
Gary

[Insanity-74]

The only way to swap the pump is by removing the tank - end of story.
Gary

Unfortunately it is the only way. There is another option though, if your pump is OK and your only doing this to "Upgrade" then fit a swirl pot which is fed by the standard pump, as it dosnt need to create pressure for this job it can pump at a far greater rate than normal. Then have a remote "Race" pump fed by the swirlpot, supplying the feed and pressure to the fuel rail.