Fuel Pump replacement (evo 4,5 & 6)
This guide is for the CP9a (Evo 4,5,6). For the Evo CT9a (Evo 7,8,9) you access the pump through an access hatch under the rear seat. It is very easy compared to the earlier cars.
Car Jacked up and on axle stands.Prop moved to one side and the tank virtually out.
Fuel Pump Top, the left hand side is the one to remove ;)
OEM Fuel Pump
New Fuel Pump
First off an apology.
When i replaced my fuel pump, i took alot of pictures, in great detail, as it was the first project for this site infact.Now that i`ve come to write this page, can i find them? NO! :( Done a complete search on the pc, all 160 Gb of it, and come up with nothing! So what you see to the left are a few pictures that i took while we changed the pump on my m8`s Evo6 instead.Low quality and not intended for a tutorial, they are all i have.
The job in its self isnt difficult, but be prepared for rusty clips on the rubber pipe that fastens the filler neck to the tank, petrol and other debris entering your eyes, and an aching neck if your doing the job on your back like i did! :)
1.Drive the car until virtually empty.
2. In the event of no car ramp/ramps, jack all four wheels as high as possible off the ground.
4.Mark up where the prop shaft fastens onto the rear diff.Undo the prop shaft bolts and remove, leaving one in.Undo the two centre mounts for the prop, and remove the remaining bolt that joins the prop to the rear diff.Lower the prop to the floor, taking care not to allow the prop to drop out the front diff.If it does, simply push it back in.
5.Follow the large flexable hose from the rear right of the tank to the filler neck.Undo the clip, along with the vent pipes clip above it too.Remove the two pipes at the filler neck end.
6.Undo the mounts for the handbrake cable, and other wiring too.Push to the side out of the way.Disconnect the petrol lines.The clips undo by pressing the green tabs inwards, and pulling apart at the same time.
7.Unfasten the four fixing nuts that hold the tank to the underside of the body work, and allow the tank to drop. Manoeuvre around the rear diff (bit tricky) and drop to the floor, undoing the clips for the wiring as you lower.Disconnect the tank and pull from under the car.
8.Remove the left had side cover.Replace the pump for the new one.They are a like for like swap.
9.Replace tank in reverse of removal.
10. Start car and check for leaks.