Just wondered if anyone else has replaced their pump w/o removing the tank. After reading up on this job and 1. realizing those lower lines are a b*tch to get to and 2. it failed just after filling up tank, I opted for going thru the package tray - It was remarkably easy, pulled required interior pieces then used air nibbler to make access hatch, used no tools or lights that would create heat/sparks, wore filtered mask to keep passing out on fumes , covered arm to dip into fuel, very careful not to drip anywhere


replaced pump

Put everything back together, no can tell

Done

 

How did you close up and seal the access hatch you cut with the air nibbler?

 

since that area is not visible and not exactly critical to structure rigidity I simply folded metal back into position and used aircraft metal tape to seal. Once everything is back into position ie. sound insulation & interior tray its all good

I figure they would not put a speaker hole in there if it was that important for to be solid & strengthening things, its not like I removed much anyway

 

I left mine open incase I have to replace the pump again sometime. The trim that also hold the speaker grill in place covers the opening nicely.


The key is to never let the fuel level get below 1/4 tank because the pump gets its cooling from the fuel.

 

I have some questions:

1. How big a hole do you need to cut into the parcel shelf?
2. How do you get access inside the tank? I am told that a special tool is needed to remove the flange assembly on the top of the tank
3. Where is the pump located inside the tank, and how easy is it to remove/replace?

 

Hi badger2196,

Use the forum search function - in the past someone has posted photos showing how to replace the fuel pump via the parcel shelf. It's a well-known method on the X308.

Cheers,

Don

 

Well yeah, except that none of the searches I tried gave me the info I'm looking for - they were mainly about removing the fuel tank. The one and only promising thread had a link to a site that was invalid.

 

Mine was 8" X 4.5" Use a brass or bronze drift to remove/loosen the lock ring. Use a fuel transfer pump from Autozone, Advance Auto, etc. to pump down the fuel level into gas cans. The pump is down inside the tank close to the bottom. Attached are a couple of photos showing the opening that I made. You gain access by removing the light blue vapor collection device.

 

Very important; brass or bronze will not strike a spark against the steel of the tank. Good point.

Other is that the battery is disconnected (obvious), and keep the doors open as well as the boot to keep down any concentration of fuel vapor (and obviously, the garage door...) or do outside.

And keep a fire extinguisher handy. Just in case. Better to have at hand and not need than to need and not have at hand.