G50 - 94 Fuel Pump Replacement - N00bie thoughts (and 2 Qs for experts)

[chomer]

Just completed my first fuel pump replacement on the "new" G50 I just got 2 weeks ago. I'm sure there's a lot of collected thoughts out there, but here's my experience for someone else that might do the job soon. And this is based on my thoughts while reading the info sheet that was posted on the fuel pump removal here and also on q45.org.

1) I've owned the car for roughtly 3 weeks. I've put over 1000 miles on the bad pump. How badly did it hum? Well, let's just say that it sounded like the antenna motor was running all the time. Sometimes (with a fuller tank) it would sound less. Sometimes more.

2) Pulling the fuel pump was straightforward. Except for pulling the rear seats and rear deck. Perhaps it's because I'm 6'4 and only weight 175, I didn't feel pulling the rear seat and deck to be useful. I did all my work from the trunk. As a matter of fact, the pump even came out that way. My assembly had the fuel level gauge on it, and that was the end of the "C" shape. Swapping the fuel pump itself was easy. Just make sure the gauge doesn't break when you put it back in.

3) Pulling the rear seat only allowed easier inspection of the gas tank. Personally, I would have been just as happy with a nice mirror and a strong flashlight.

4) Fuel pump controller "seemed" ok. I pulled it out. I don't know in the big write up whether it's because the bracket changed for 94+, but pulling the 2 10mm bolts under the rear deck didn't help pull the FPCU. As a matter of fact, it didn't do a thing. Upon closer inspection, it appears that the FPCU on the 94+ is held on with 2 10mm nuts. Loosen that up, and the FPCU comes *right* out.

5) I looked at the FPCU and opened it up. No burnt connectors, nothing smelled funny, no large solder beads/joints/bubbles. Except for a bead that was stuck to one of the screws on the corner of the circuit board. Seems to be a manufacturing defect, but I can't be 100% sure. However, if this is bad, it's easy to swap out without doing anything else. On the 1000 miles I drove, I kept it below 2000 rpms, except on the freeway where I would keep it below 2750 rpms (85 mph), and never downshifting to accelerate. People think I'm the old FL driver. =)

6) I can't find the relays. I think they're behind the trunk liner on the right. But.... I was wrapping up the job @ 11pm. And didn't want to look for it. I'll check in a bit. Any expert thoughts on this?

7) Open the gas tank, get a lot of rags, and I should have cranked the engine to remove all fuel. I broke the 3 metal pipe "holder", but only on the far left side. That should be ok... but no guarantees. I'll keep an eye for it.

Hopefully, these observations might help someone else doing their fuel pump on a 94+ Q.

And of course, I want to thank everyone on this board for the great advice. It made it go much easier, and unfortunately couldn't take more pictures to help things out.

[Q451990]

Removing the rear deck finisher and center storage box gives you easier access to lift the pump and delicate sender assembly up and out of the tank without bending anything.

As far as removing the FPCU, I'm not sure how you did it w/o pulling the rear deck. To my knowledge this part of all 1990-1996 Qs are the same. With one 10mm bolt holding it on from the top side. If I remember correctly, the FPCU bracket is spot welded on to the unit - so I really don't know how else you would get it out. Are you sure you inspected the FPCU?

Anyhow, I'm glad to hear you got it replaced!

Heath