Just wanted to add my thanks to Bunny and Planenut for their great article on fuel pump replacement. Used it today to preemptively replace the fuel pump in my car with a Walbro GSS242. Hardest and longest part of the project was getting the black plastic weathershield off. Have decided to live without it now that I have a decent rear mudguard. The only thing I might add to the directions is to make sure the fuel system is fully depressurized, like overnight, before removing fuel lines. Any residual pressure in the system will soon become dramatically apparent, as I found out. :o
I was amazed at the amount of what appeared to be aluminum shavings in the sump/tub that the pump sits in. The fuel tank itself looked fairly clean inside from what I could see. Sorry I forgot to take pictures.
Speaking of the sump tub: with fuel ingress possible only at the top of the tub, it means the last 4 plus inches or so of fuel in both tanks is unusable, which is about 1/3 of the tank height, and therefore capacity! Pretty silly, it seems to me, to haul around 4 gallons of fuel you can never use. The Land Rover from which the fuel pump assembly comes must have some sort of deeper sump arrangement. So after thinking about it for a short while, I drilled three half inch holes near the bottom of the tub, which should give near complete use of all available fuel, should I ever need it.
Should you decide to do the same, note the sump tub is fairly brittle, so start with a small bit, then use a step bit if you have one. I went from an 1/8" bit to a two flute 3/8" one and it "chunked" out a small piece of the tub. Changing to a single flute step bit provided smooth controlled cutting.
