I'm terrible at taking pictures during a project. I get focused on the task at hand, and when I think about pictures, it's usually almost wrapped up.
I utilized 3 pumps for this setup, and converted to a return-style system. I believe the stock pump (flex fuel vehicle) is rated at 255l/hr, and I bought two additional 255l/hr pumps (E85 compatible), for a total flow rate of 765l/hr. Granted, those flow rates are probably at 43.5psi, and I plan to run a base pressure of 58-60psi, so I'm probably in the 700l/hr range for total flow.
Anyways, here are the steps I took to get it done (2007 Avalanche). You want to do this on a lift ideally, but it could be done on jack stands as well, you just need about 20" clearance between the tank and the ground.
1. start with a fuel tank that is 1/8 full.
2. disconnect the following items:
- Rear portion of fuel tank:
-- fuel filler hose,
-- 3 plastic lines for the charcoal canister (2 @ 17mm, 1 @ 13mm),
-- 2 plastic lines on top of the fuel tank (one is about 17mm, the other is about 10mm),
- Front portion of the tank:
-- 1 plastic line, 10mm diameter (front right top corner of tank)
3. Grab a buddy, or place a floor jack with a 2x10x38" or 2x12x38", and support the tank
4. Using a 15mm socket, remove the bolt that secures each tank strap
5. Slowly lower the tank about 4-5". The rear has to come down first, as the front of the tank sits in pocket created by a chassis brace.
6. Once down about 4-5", wiggle your way up so that you can see the top of the tank. There are 2 electrical connectors and 2 more plastic lines that have to be disconnected BEFORE you can lower it the rest of the way. I found that a pair of curved jaw needle nose pliers worked nicely for removing the 2 plastic lines.
7. Once everything is disconnected, you can finish lowering the fuel tank.
8. Once the tank is on the ground, or workbench, you need to remove the fuel pump locking-ring. There is a special tool for this, but I have found that a drift punch and hammer work also, just have to use a little patience and care.
9. With the lock-ring removed, the fuel pump module can be lifted partially out of the tank to expose the last plastic hose connection. Once disconnected, remove the pump module from the tank. It will be full of fuel, so once out, just tilt it on its side to drain the fuel back into the tank.
-- additional posts to follow --
-Scott
