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Fuel pump - cutting an access hole???

16K views 20 replies 9 participants last post by  JK  
#1 ·
So, tomorrow I will need to replace the fuel pump in the 9-3 since it left Jen stranded today (luckily it left her stranded at home, rather than away from home).

Anyway, I swear I've heard that some people have cut access holes in the floor to replace the fuel pump, I'm just wondering if anyone can elaborate on this...I'd really love to avoid dropping the FULL tank of gas that's in there, and seeing as how my jack is currently out on loan, it would be nice to be able to do this without going under my car.

Thanks in advance
-Jessop
 
#3 ·
I'll hold off on needing the jack, because I'd much rather cut a hole...but if I need it I'll let you know, I could even pick it up, since I need to do a little test driving of my car later, but for now I'll wait/search for some clues to the hole idea.
 
#6 ·
Now that I've read up on that thread I will certainly be cutting a hole. I also checked in the 9-3 and it's pretty darn clear where the hole should be (as in where it should have been from the factory).

Barring a non-working camera I will take photos of the progress tomrrow and let everyone know how it goes!
 
#20 ·
oh, and rather than using a shoplight or something silly, i reccomend one of these for this job:

Image


much much brighter...

Paul
I'd advise using an oxy-acetylene torch, plasma cutter or a grinder. All of which seem like excellent choices.
yes and then when you are putting it back together, make sure to weld that panel back in, preferrably with the same oxy-acetylene torch you cut the hole with.

so how much bad advice can we give in one thread? :lol:

Paul
I hear if you douse metal in jet fuel, it's eaiser to cut with a torch.
Ok, you ALL win free tequila shots if you make it to SOC. I will buy some fine (read: cheap) tequila just for this purpose.

If any of you are too pussy to help me finish a bottle of tequila then you can have a shitty (warm) beer on me.
 
#11 ·
probably in a good rear ender, the pannel poped off or something since it would not haven been totaly paralal to the floor. It's a great idea cutting that access pannel, but personally I'd probably keep the sheet metal square and attach it back on there with hinges or something. many of these really really bad accident cars I have seen in the junk yard, having a hole right above the gas tank would have been a really bad thing...

Paul you remember that volvo 850 at shortys? the back seats were gone from the impact and there were driver bits in the front seats... Having a large section of exposed plastic gas tank in my back seats would be a tad on the worrysome side.
 
#21 ·
-Fuel pump is in

-camera not working (so no photos)

-hole in floor sealed up with the metal that I cut out, as well as some rubber, silicone/urethane adhesive caulk and duct tape...yes, lots and lots of duct tape to keep it in place until the caulk seals it up.

The car runs, and hopefully will keep running for a while, or at least until I replace the pump insert on the pump that crapped out. The pump that's in there right now is a used unit that I got from work.