Replacing fuel pump in '05 Elise - LotusTalk

gibbsb · 10-29-2009, 09:19 AM

Anyone got a time estimate on this job?

Thanks,

Barry

turbophil · 10-29-2009, 10:37 AM

05s take a while as the hole is too small for the filter assembly, thus a total PITA to remove... Instructions on my webpage...

Good luck!

Phil

MaineLotus · 10-29-2009, 10:47 AM

Quote:

Originally Posted by gibbsb

Anyone got a time estimate on this job?

Thanks,

Barry

If you trim the access hole with a Dremel to allow access (recommended), I'd estimate 2 hours, not rushing.

kverges · 10-30-2009, 06:54 AM

2 hours!!!!!!!!!!

I have done this job on a 2005 and no way it takes 2 hours. Basic steps:

Drain fuel
remove undertray
remove shifter cables and e-brake cables
remove seats and rear panel with speakers in it
remove internal access cover for fuel pump module and disconnect electrical and plubing lines
remove panel under fuel tank (plenty of bolts here as it is a stress member for vehicle and rear suspension)
remove fuel tank mounts and drop tank
Destroy fuel pump module in effort to get it out of undersized hole
Trim hole with dremel for new fuel pump/sender module
carefully and throughly clean tank for debris from last job
reinstall new fule pump module and put everythgon back, taknign great car to, among other things, carefully torque the panel under the fuel tank.

If you can do all that in 2 hours then you are moving on out!

I'd estimate minimum 6 hours and that's if you have done it before.

ads_green · 10-30-2009, 07:32 AM

you can replace the fuel pump without disturbing the tank.
Its just more fiddley as space is limited.

MaineLotus · 10-30-2009, 07:44 AM

Quote:

Originally Posted by kverges

2 hours!!!!!!!!!!

I have done this job on a 2005 and no way it takes 2 hours. Basic steps:

Drain fuel
remove undertray
remove shifter cables and e-brake cables
remove seats and rear panel with speakers in it
remove internal access cover for fuel pump module and disconnect electrical and plubing lines
remove panel under fuel tank (plenty of bolts here as it is a stress member for vehicle and rear suspension)
remove fuel tank mounts and drop tank
Destroy fuel pump module in effort to get it out of undersized hole
Trim hole with dremel for new fuel pump/sender module
carefully and throughly clean tank for debris from last job
reinstall new fule pump module and put everythgon back, taknign great car to, among other things, carefully torque the panel under the fuel tank.

If you can do all that in 2 hours then you are moving on out!

I'd estimate minimum 6 hours and that's if you have done it before.

I did it in less than 2 hours. The longest part was seat & harness bar removal. I trimmed the access port with a Dremel to allow removal WITHOUT dropping the tank. Once I had access to the pump housing, it was a 15 minute swap.

ZTEC · 10-30-2009, 09:30 AM

I really think this is partly luck of the draw - some are much easier than others, I spent about 3 hours doing this swap when I added the 255 walbro for the VF stage II pump and you just got to be patient and work it back and forth while the housing gets shaved by the opening lip as you carefully work it. There is a hole "about 3/4" in the firewall that I got it started with a flat blade screwdriver from the engine side and just worked it little by little until it popped out ( what a glorious moment

) and then trimmed the plastic housing with a dremel before reassembly! I did have to get creative with a couple of "Hooks" to grab the lip as I pulled side to side trying to keep the housing from binding but it will eventually come out with some effort! Good Luck!!!

kverges · 10-30-2009, 12:52 PM

My pump module was so tight that even with the tank out of the car I broke the entire flange off of the unit trying to pry it upward and no way could I have gotten it out while trying to reach in the cavity with a screwdriver. I also am not a fan of the amount of cutting I have seen on the chassis to make room to extract the module through the chassis instead of dropping the tank.

But if you get lucky and can get the module loose and are willing to cut the chassis, then it coud be done in 2 hours that way.

10-29-2009, 09:19 AM	#1 (permalink)
gibbsb Registered User Join Date: Aug 2009 Posts: 3	Replacing fuel pump in '05 Elise Anyone got a time estimate on this job? Thanks, Barry

10-29-2009, 10:37 AM	#2 (permalink)
turbophil Plug Whisperer Join Date: Dec 2005 Location: Kansas City/ Overland Park Posts: 2,545 Images: 6	05s take a while as the hole is too small for the filter assembly, thus a total PITA to remove... Instructions on my webpage... Good luck! Phil __________________ \| '05 GG LSS Elise \| A Track Chariot \| BOE ClamHinge \| BOE TVS SuperCharger 280whp/180wtq \| EFI Standalone Engine Management \| BOE Fuel Surge System \| BOE Lotus Tow Package See my car at BOE Fabrication: www.boefabrication.com *----->Last Updated: 9/25/2009* If something ain't worth doing right, it ain't worth doing... *Whoever thought working on a Lotus is hard, clearly hasn't tried it. Pick up a wrench and get some grease under your nails*

10-30-2009, 09:30 AM	#7 (permalink)
ZTEC Third Eye Open Join Date: Jan 2006 Location: Florida Posts: 1,738 Images: 3	I really think this is partly luck of the draw - some are much easier than others, I spent about 3 hours doing this swap when I added the 255 walbro for the VF stage II pump and you just got to be patient and work it back and forth while the housing gets shaved by the opening lip as you carefully work it. There is a hole "about 3/4" in the firewall that I got it started with a flat blade screwdriver from the engine side and just worked it little by little until it popped out ( what a glorious moment ) and then trimmed the plastic housing with a dremel before reassembly! I did have to get creative with a couple of "Hooks" to grab the lip as I pulled side to side trying to keep the housing from binding but it will eventually come out with some effort! Good Luck!!! __________________ GO: Vision Function Stage II Intercooled Bliss with Charlie's ECU magic and Ronin's Tenacity! STOP: DBA 4000's, Porterfield R4! TURN: Nitron S/A's Toyo RA1's 225/245 on Rota's!

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10-30-2009, 06:54 AM	#4 (permalink)
kverges Registered User Join Date: Feb 2005 Location: Dallas Posts: 927	2 hours!!!!!!!!!! I have done this job on a 2005 and no way it takes 2 hours. Basic steps: Drain fuel remove undertray remove shifter cables and e-brake cables remove seats and rear panel with speakers in it remove internal access cover for fuel pump module and disconnect electrical and plubing lines remove panel under fuel tank (plenty of bolts here as it is a stress member for vehicle and rear suspension) remove fuel tank mounts and drop tank Destroy fuel pump module in effort to get it out of undersized hole Trim hole with dremel for new fuel pump/sender module carefully and throughly clean tank for debris from last job reinstall new fule pump module and put everythgon back, taknign great car to, among other things, carefully torque the panel under the fuel tank. If you can do all that in 2 hours then you are moving on out! I'd estimate minimum 6 hours and that's if you have done it before.

10-30-2009, 07:32 AM	#5 (permalink)
ads_green Registered User Join Date: Oct 2008 Posts: 366	you can replace the fuel pump without disturbing the tank. Its just more fiddley as space is limited.

10-30-2009, 12:52 PM	#8 (permalink)
kverges Registered User Join Date: Feb 2005 Location: Dallas Posts: 927	My pump module was so tight that even with the tank out of the car I broke the entire flange off of the unit trying to pry it upward and no way could I have gotten it out while trying to reach in the cavity with a screwdriver. I also am not a fan of the amount of cutting I have seen on the chassis to make room to extract the module through the chassis instead of dropping the tank. But if you get lucky and can get the module loose and are willing to cut the chassis, then it coud be done in 2 hours that way.

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