Subaru SPFI fuel pump repair
Actually, original equipment Subaru fuel pumps aren't bad. I have only had one fail.
But new ones go for around $300.00!!! I decided to use one of the spare ones I had
removed from an ex-car. Unfortunately, the thin steel of the fuel damper was
rusted through. How many of these things are really needed?
There are 2 more in the system in addition to the one on the pump, and a spare in line
one could be added to replace it.
Before beginning modification of the pump, I connected a source of low pressure low
volume air to the pump intake. One reason is to blow out any gasoline and or vapor
in the pump, and to help prevent bits of metal from cutting & grinding from getting
into the inner workings. Run the air through for a good while, then hacksaw the
damper off, leaving as much outlet tube as possible.
The steel outlet tube is pretty thick walled. A 7/16" NF tap cuts threads nicely
into the end of the tube, and a slice of 7/16" NF bolt makes a nice plug. While
tapping, hold the pump with the inlet up so the chips don't fall into the pump.
The pump ready to solder the plug.
The pump is strapped to a block of wood. Wire ties hold the power wires out of the way.
Pieces of aluminum flashing keep the heat away from the wires, and do not touch the
wires or insulators. Water is trickling over the outlet pipe and spread with bits of
paper towel to prevent heat from damaging internal parts. Low pressure air is flowing
through the pump also to cool and keep anything from going into the mechanism. I used
Oatey lead free tinning flux and 60/40 tin lead solder.
After soldering. Before installing, coat with Waxoyl or your favorite rust preventative
undercoating material.