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DeatschWerks DW300 fuel pump install


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Installed my DW300 fuel pump today. Would have been a lot easier if I hadn't filled the tank on Monday. I would recommend anyone attempting this install start with much less gas in the tank (1/4 or less).

 

Pull the fuel pump fuse and then crank the car over a few times to release pressure in the fuel system. Then replace the fuse.

http://i.imgur.com/HOAFK01.jpg

 

Since I had a full tank, I had to drain out as much fuel as possible. Disconnected the fuel feed line under the hood and attached 6ft of extra hose and ran it into a fuel can. Keyed the car on and off to keep the fuel pump running and filled both of my gas cans. 7.5gal later my fuel gauge was just a hair over 1/2 tank. Service manual says to have less than 2/3 tank, so I figured I was golden.

http://i.imgur.com/dbrKQIe.jpg

http://i.imgur.com/xd7Z8DS.jpg

http://i.imgur.com/BxWFX2s.jpg

 

Disconnect the negative battery terminal.

 

Pulled out the rear seat cushion. No tools needed, just pull up on the front edge and the two fasteners will pop out. Then maneuver the cushion to release the hook in the center, between the seatbelt buckles.

 

The panel on the passenger side is the one for the fuel pump.

http://i.imgur.com/8My3oAJ.jpg

 

Remove the 4 screws holding the cover on. Also remove the plastic clip holding the fuel pump power cable. Then push the rubber grommet inside the cover and remove the cover.

http://i.imgur.com/8My3oAJ.jpg

 

It was pretty dirty in there, so try to get as much dust and crap out as possible. You don't want all that junk going into your gas tank!

http://i.imgur.com/sPp2uBK.jpg

 

Remove the 8 nuts holding the fuel pump assembly into the tank. There is one under one of the fuel lines under a rubber cap. Be sure not to lose that cap! Unplug the wire harness and disconnect the fuel hoses. Half a tank wasn't low enough, fuel went everywhere when I tried to pull out the pump. Make sure you have as little fuel in the tank as possible if attempting this yourself. Also have lots of rags around.

 

I ended up having to bend a bit of sheet metal with pliers in order to remove the bracket on top of the fuel pump.

http://i.imgur.com/C9aqrU3.jpg

Edited by Rutchard
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Pull out the fuel pump housing and be very careful not to bend/break the fuel level sensor as you remove it. Set the housing someplace somewhat clean and prepare to disassemble.

http://i.imgur.com/5lmbxdJ.jpg

 

Unplug the fuel level sensor and the fuel pump wire harnesses.

http://i.imgur.com/EyLazlb.jpg

 

Release this tab and pull the housing apart.

http://i.imgur.com/AqbG567.jpg

http://i.imgur.com/SgkinNX.jpg

 

Unplug the other end of the fuel pump power harness, you might not have enough room to pull the plug, but just get it loose for now.

http://i.imgur.com/EqOkf6V.jpg

 

Pry and remove this collar holding the fuel pump in. Be careful not to break the plastic or gouge out the plastic with your screwdriver. Plastic shavings in the pump housing probably wouldn't be good. Lets not find out!

http://i.imgur.com/nJfGN8p.jpg

http://i.imgur.com/qDg1ykS.jpg

http://i.imgur.com/vD6A32T.jpg

 

Now you can pull out the stock pump, it's in there pretty firmly but will come out eventually.

http://i.imgur.com/5qyEXyG.jpg

 

Stock pump next to the DW300

http://i.imgur.com/Y9uN2eu.jpg

 

Pull this black rubber piece off of the stock pump and install it on the DW300.

http://i.imgur.com/TQPyBce.jpg

http://i.imgur.com/XVwOF0J.jpg

 

I also already installed the new fuel filter sock at this point. Now you can insert the DW300 into the pump housing. Plug in the wire harness.

http://i.imgur.com/YtbSXf2.jpg

 

And push the pump all the way into the housing.

http://i.imgur.com/rzw2Z5c.jpg

 

With the stock black rubber spacer on top, the plastic collar won't fit.

http://i.imgur.com/1KwAASk.jpg

http://i.imgur.com/f8H9ovc.jpg

 

Without the spacer the collar pops on snugly and the pump stays in place.

http://i.imgur.com/vAh64uS.jpg

 

There was a lot of nasty crap inside the fuel housing, so I flushed it out before putting everything back together.

http://i.imgur.com/CS878aD.jpg

 

Reinstall everything in reverse order. Don't forget the rubber cap when reinstalling those 8 nuts. Don't install the cover or rear seat yet. Re-connect the battery and key the car to on but do NOT start the car. Repeat this a few times and look around the top of the fuel pump to make sure all the lines you reconnected aren't leaking. If everything looks good start the car and let it idle for a little bit. Check again for leaks and again, if everything looks fine, then you can put the cover back on and reinstall the back seat.

Edited by Rutchard
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I think I already have my answer but would any efficiencies be gained by having a better pump installed on a N/A car? Not that it needs more fuel but maybe better delivery of the required amount.
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I think I already have my answer but would any efficiencies be gained by having a better pump installed on a N/A car? Not that it needs more fuel but maybe better delivery of the required amount.

 

No.

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  • 6 months later...

Mine weren't ID's, but they were plug & play. I honestly didn't feel like messing with it. Was easier to just pay someone who knew what they were doing. Plus they were installed 10ft from the dyno so I didn't have to worry about getting a limp map to drive to the shop on.

 

Innovative said it was a little more difficult than the previous gen because the charge pipe is in the way on the passenger side.

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  • 3 months later...
I would like to throw a big thanks to Rutchard. I just put my DW300 in today and followed this awesome writeup. Had my Ipad out scrolling through the pics while I did it step by step. So THANK YOU Rutchard. If we ever meet, I'm buying you a pitcher of whatever beer you want.
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  • 3 months later...

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