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Old 01-29-2012, 08:34 PM   #1
Overland04
Scooby Specialist
 
Member#: 293311
Join Date: Sep 2011
Chapter/Region: NESIC
Location: Coast of Maine
Vehicle:
2013 FXT 6-Speed
Obsidian Black Pearl

Default New DW65c Fuel Pump step-by-step install

Hey Forum,

Today I added the new DW65c Fuel pump into my 2011 WRX. Here is a full write up of the install.
If this works out well for you, check out my 2011 WRX build thread over here! I have many more install threads...

To start off, I left the car overnight to release as much pressure from the system as possible. It is also nice to have the least amount of fuel in the tank. I had nearly a full tank and it made things a little harder when it came to taking the assembly out of the tank.

*Remove the negative terminal from the battery and unscrew your fuel cap.*

Tools needed are:

A clean area (preferably not outside)
Phillips screwdriver #2
2 - Flathead screwdrivers, small
8mm socket with 1/4" ratchet
Needle nose pliers, medium
Rubber gloves
12"-15" Glass or Pyrex dish. (I used a pie dish)
Paper towels
Glass surface to work on with cardboard underneath
Fire extinguisher (safety first)
DW65c pump with filter, o-ring, grease

Start off by removing the rear seat bottom. To remove, locate the two little black plastic pull tabs under the outside corners. Once the outside is released, find the center point of the seat, reach underneath and pull straight up.






Once the seat is removed, you will see two silver removable covers. The one you are looking for is on the passenger side with the warning labels on it.




Unplug the harness that is coming out of the cover and remove the four Phillips screws. Once the cover is off pull the harness and grommet through the hole. The foam can come off now too. Try to remember its orientation, its not the end of the world if you don't but it helps.



Now it's time to remove the electrical harness from the assembly. Once that is unplugged bend it off to the side to make as much room as possible.
Next is to remove the fuel lines. Use paper towels like the below picture to gather as much fuel leakage as possible. Please move slowly as unplugging the fuel line is messy if not prepared properly. There WILL be fuel leaking out... It's unavoidable. The trick is to NOT get ANY on your carpet!
Now, using your needle nose pliers slightly squeeze the retainer clip that is front of the fuel line connector. Once squeezed, SLOWLY pull the fuel line away from the housing. On the first line you may still hear pressure release. Get ready to catch the leaking fuel as you get the fuel line away from it's connector.
Repeat for all three lines.




Once all three are removed, clean the area free from tools and all dirt that is visible. The next step will be to remove the cover so anything can get in the tank. I'm pretty sure you don't want to have to fish your hand in the tank if you drop something in there!





Next, you remove the surrounding 8mm bolts that hold the black metal ring to the tank. The top black metal ring holds the assembly down. It is slightly spring loaded so as you remove the bolts, unscrew them but don't completely remove them until all of them are almost off. Then one by one while holding the assembly down, remove them.
Now that the black metal ring is free, you can remove it.

*Glass pie dish is perfect for the next step*

I suggest you look ahead to see what the assembly looks like before you remove it. Reason is that there is the fuel level float that sticks out and you need to tilt the assembly as you remove it. If you bend the bracket or break it, your screwed... SO PAY ATTENTION!

While holding back the thee fuel lines with one hand, use the other hand to slowly lift the assembly looking out for the fuel level float while doing so.
Have your glass container ready to stick underneath the assembly as you lift it completely out of the tank.





Now that the assembly is out, it's time to disassemble.
Please don't work on any surface that is unfinished wood, carpet, painted, plastic, or dirty. I used a glass storm door covered in cardboard.



The first step in the disassembly process is to unclip the four larger white tabs around the assembly. You may need four hands if you have them...
Once uncliped, separate the two pieces by pulling them apart.



This is how it will look when you get the assembly separated. There is a lot of fuel in the bottom half, be careful not to tip it over while prying the two pieces apart.


Last edited by Overland04; 02-06-2012 at 04:23 PM.
Overland04 is offline   Reply With Quote
 

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