I'll be putting a new fuel pump and sending unit in my 91 Formy. I've never done this before and since the old unit was taken out by the previous owner (and lost), I have no idea how all of this stuff goes together and the documentation that comes with them kinda stinks.....

Does anyone have a pic of their assembled pump/sender?

Also, the new sending unit has the lines going all the way to the fuel filter, etc. Can I install it as is, or do I HAVE to cut the lines (coming out of the tank) and mate them to the stock lines still on the car?

Again, ANY help would be great, this is something I've never had to deal with before.

Here's the complete package, pump and sending unit:



The extras from the sending unit:



The Bosch pump and accessories that came with it:

 

I unwrapped everything and it LOOKS straightforward on mounting the pump.

Again, since I didn't have the old parts to begin with, I'm flying a little blind here....

The pump and the sender came with a rubber sleeve for the pump to fit in - I've read a few places that this isn't used - Can anyone confirm?

As far as mounting the pump itself, it looks like you use the small amount of rubber hose with the two clamps to go from the pump to the hose... There is a shaped isolator that goes on the bottom of the pump, where it sits in the sending unit assembly - Then, I assume that you just push the strainer/filter sock on the end of the pump itself. Is that it??

Assuming that the above is correct, here are some parts/pieces that don't seem to be used (minus the pump of course)... is that right?

 

ANYONE?!?! I'm dying to put this thing in the new tank!!

 

That's pretty much it.

Not sure why you'd want to cut ANYTHING??

Looks to me like you disconnect your car's lines and filter and stuff from the existing sending unit; put those new lines and sending unit and pump and all into your tank; re-install the tank; and hook them back up.

Why would ANYBODY ever want to cut ANYTHING?? I've never understood that.

That little piece of rubber hose at the pump output is a common failure item shortly after replacing it. Might be a good idea to go somewhere and get THE BEST QUALITY FUEL-RESISTANT HOSE you can get your hands on. Might save you a re-pete (you know, one of the 2 mechanics that work at your favorite shop, good ole Pete and Re-Pete) not too far down the road.

 

Well, the original lines in my car where cut when the P/O decided to cut and access hole in the trunk area. I think I'll just go ahead and weld it shut.

Anyway, my original lines were cut and EVERY other "access hole" I've seen looks like this:



...and has the clamps over some fuel line (or fittings) to mate everything back together.

My sending unit came with one and the Bosch pump came with another. The Bosch one looks beefier, I'm gonna see if I can identify it and just go with that one.

[edit] I just put it all together, as I understand it to go together. I assume this is correct?

 

Oh yeah, do I need a "fuel pump pulsator"? I see one is listed for my car at the parts store, but since I don't have the complete OEM setup, I don't know if I need it.

[edit] Nevermind about the pulsator - I'm not going to use one.

 

That all looks right to me...

The "pulsator" would go in the tank in the stock pump/SU assy, between the pump and the outlet line, basically where that rubber hose is. Looks like that replacement setup doesn't use it. So no problem there.

Looks to me like all you have to do is disconnect the lines right there at the front driver's side of the existing tank (the stock ones are basically just like those new ones), throw all that hose-clamped trailer-trash alternative-ethnic rigging away, put your new tank in right, and fix the hole; and you'll be good to go. The only opportunity for improvement that I see is that little short piece of rubber hose on top of the pump itself, which is known to be risky in replacement pump setups.

 

Did You ever get the fuel pump in?