The reason I am posting this up is because although there are a handful of DIYs, there is a major step wrong with them and we all want this info on ephatch, not crsx or something. So here we go.
NOTE: it is a good idea to replace the fuel filter when doing this.
Photobucket changed their hosting policies and all photos down. Send me a PM (and be patient) and I can send o you or post on facebook or something.
Fuel system part numbers (Majestic numbers and Honda):
26488 - Gasket, Base - 17574-S1A-E01
368416 - Holder, fuel pump - 17049-S5A-930
368409 - Housing, fuel pump - 17042-S5A-930
1093205 - reservoir (denso) - 17043-S5A-941
368411 - cap, reservoir - 17044-S5A-930
399254 - filter set, fuel - 16010-S5A-932
1077164 - Regulator Assy. - 16015-S6M-930
368406 - Wire, lead - 16016-S5A-930
1077176 - Pump Set, fuel - 17040-S6M-930
Parts list
Gates submersible fuel line - MUST BE SAE 30R10 RATED!!!!
If you do not get the right hose, it will melt/disintegrate in the gas. Purchased from NAPA.
All the DIYs skip this step and call for a braided or regular line.
http://www.gates.com/brochure.cfm?br...ocation_id=541
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Some long zip ties
Some small stainless steel hose clamps
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Walbro fuel pump number GSS342
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Various tools like screwdrivers and a dremel or good utility knife.
Prep the car by removing the back seat, unscrewing the cover plate over the gas tank, and disconnecting the fuel line and wire harness...have plenty of rags handy.
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Next, the easiest way to get the big collar off is using a big ass wrench but they don't make one aside from the special tool. First time I took it off, I used a coping saw arm. This time, I used a bent piece of 1" steel bent in a U
shape. This is bought from Home depot for like $5. Keep in mind this is needed to remove AND reinstall the collar.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3822.jpg
Take off the collar and pull out the fuel pump/filter assembly. Since I am not able to run the car down to empty, I will have to drain the gas. I pulled it out just a bit.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3824.jpg
Siphoning out gas
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Fuel pump assembly out
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Disassemble the the assembly. Be careful! Look to see how it is all put together so you don't break anything during this step.
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Here is why I am doing this, the bracket cracked from a rock hitting the precise point where my pump was and then after fixing it, it cracked again...I know, I should have replaced the bracket but I was not smart.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3828.jpg
You will have to cut the stock pump bracket for the hose to connect. I was fortunate enough to have that piece cracked off mostly, so i just finished the job. Once you see it back together, you will know how much extra may
need to be cut to install zip ties.
Next, start the reconstruction subbing in the walbro for the stock fuel pump.
The Walbro will be longer than the stock but don't worry, it will fit.
You will need to attach the hose after adding the bracket, front, and back pieces.
Use a hose clamp for the pump connection.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3838.jpg
Add the zip ties as shown or as you see fit. Keep in mind there is not unlimited clearance in the stock assembly
housing so trim the ties according and rotate them around to not prevent closing it back up.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3842.jpg
Next, the housing itself needs to be cut for the hose. Proceed as shown, keep in mind that the one tab there still needs to lock closed so only cut what you need.
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Put everything back together.
Connect all the harnesses and plug the other end of the fuel line to the filter.
NOTE: The submersible fuel line you need to use is only 5/16" and the connection to the filter is very tough, you
may want to try connecting this end first before hooking up the pump since that is easier. I could not get it on all the way but I got it on mostly. The SAE30R10 3/8" hose is definitely the way to go, I do not have the NAPA part number at the moment. Just ask for it. (cheaper than 5/16" anyway)
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3845.jpg
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After this, you will have to maneuver the more obtrusive pump assembly back in. You are supposed to replace the large rubber O-ring and I did. I don't have the part number on me but in retrospect, I don't think it is
essential.
Honda technician secret....use some white lithium grease so everything slides back together easier.
Use the special tool you made before to tighten the collar back down.
Hook everything back up and cycle the key to accessory II a few times to get the pressure back up and then start
it!!
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