As more and more power was squeezed out of my beloved Pearl, I knew some parts of the fuel system would eventually need an upgrade. And since the move to e85 was on the horizon, it simply made sense to upgrade to a larger and ethanol compatible fuel pump.
Instead of the usual Walbro variety, I opted for a Deatschwerks DW300 fuel pump as they’ve been offering some pretty decent products lately at a decent price. Not only that, they have fitting kits for popular makes including the S-chassis range meaning less headache.
The install itself is actually not that different to that of an R33 that Jay wrote here, but hey more car specific guides the better right?
Product used: Deatschwerks DW300 fuel pump + fitting kit (9-301-0766). For an S15 I should have actually gotten a 9-301-1024 but the difference is just the sock and base mount which isn’t a big deal since you can use your existing one.
Tools required: 10mm socket and ratchet or spanner, flat head screwdriver.
1. Go for a “spirited” drive and drain your fuel tank to less than half.
2. Pop open your fuel door and remove fuel cap to relieve pressure so you don’t fill your working area with fuel fumes.
3. Fold down rear seats and remove the carpet lining behind it to expose the fuel pump position.
4. Unscrew the 10mm bolts on the cover and unclip the fuel pump and fuel gauge connectors. Might as well take them out from the cover via the rubber grommet too so it’s out of the way.
5. Unclip and remove all three hoses, yes there will be some fuel spillage… now would be wise to suppress those nicotine cravings.
6. Attempt to twist the lid anti-clockwise with your hands, watch out for being cut by the sharp edges. If that no doubt fails, knock on the grooves gently to loosen it and then turn with your hands.
7. Disconnect the fuel level sensor connector and reach into the tank and detach the pump from the inside wall mount. Will need to push it up off the mount as it has a metal slider.
8. Notice how long the OEM sock is for an S15? If you bought the S13 kit (9-301-0766) it will have a short sock which isn’t recommended as may cause fuel surging when the tank is low, use your old sock. If you bought the 9-301-1024 you should have the long sock which is fine.
9. Your kit will have a new piece of hose so simply cut the old hose off, unplug the connector and remove the old fuel pump from the cradle.
10. If required, take the plastic mounting base off the old fuel pump, remove the locking washer using a flathead screwdriver and remove the old sock.
11. Attach sock to the new DW300 fuel pump and press in the locking washer. Attach the old mounting base also if necessary.
12. Cut up the new hose to size and attach it along with the connector to the fuel pump. Great when there’s no need to cut wires hey?
13. Maneuver the pump into the cradle (there’s only one way it can go in).
14. Now it’s ready to be popped back into it’s original position inside the fuel tank! Will take a few goes to slide the cradle back into the side mount. Remember that it has be at a certain angle aligned with the slope of the side of the tank.
15. Screw the lid firmly back onto the body, give it a few taps if needed.
16. Connect all hoses and connectors to the lid and bolt the cover back on again.
17. Screw in fuel cap and close fuel door. Prime the fuel system a few times before starting the car.
And there you have it! Told you it wasn’t so hard, just a little fiddly that’s all. And please remember to wash the fuel off your hands and change your clothes as you don’t want set yourself alight unexpectedly…