The aem pump I ordered comes with a rubber sleeve that allows this whole thing to be possible
You'll need:
- A dremel (or a file if you plan to keep this project strictly analog)
- The rubber sleeve that comes with the pump
- hose clamps for the fuel line
- aem wiring harness
To start you'll want to follow the DIY posted here to get the pump out of the car https://www.audizine.com/forum/showt...l-Pump-Install
I reccomend reading through both guides to have a thorough understanding as to what you're doing before starting.
Once you have the housing out, you can choose to remove the rubber hoses holding the middle ring in place although you can also skip this step, but I felt it makes the piece easier to work with. You should also remove the fuel line and wire harness from the OEM pump at this time as well.
Next you'll want to measure the distance and take note of how far the stock pump sits from the frame of the housing or refer to this picture.
As you can see from the second picture, the aem pump unit doesn't quite sit far enough down which is part of the reason we're doing this mod in the first place.
Once you have your distance measurement, carefully push on the pickup tube of the pump and it will start to pop out from the top. I used a piece of cardboard on a piece of carpet for padding and just pushed it against the ground. It should slide out fairly easily.
READ: Once the pump is out of the housing, I'd advise you rinse the housing and let it completely dry before getting a dremel or anything with an electric motor anywhere near it. You're probably aware if you're this far in, that you're working with a highly flammable accelerant ! Safety is key ALWAYS!
You'll want to take your dremel and carefully cut out the middle section of the bottom of the housing where the pickup tube sits. Feel free to take an exacto knife or file to the edges after to smooth it out. Make sure you don't have any plastic frays or little pieces hanging about that could possibly make their way into the tank.
Now is the moment of truth. I found it best to slide the rubber sleeve in first through the hole you just cut out leaving just a bit sticking up and then push the pump unit in through the same way. Once it gets further in it will get very hard and very tight, so much so that I have circular marks on my hand from the pickup tube. Don't push the pump all the way in!
Once you get close to the bottom you'll want to bust out your ruler and push the pump in until the pickup tube is the same distance as the OEM unit. Trim away the excess of the rubber sleeve that sticks up if you feel inclined.
Once you've done that you're just about done. Wire the harness from the aem pump to the OEM harness or install your own connector onto the aem wires and attach the fuel line . I found that positive on the OEM harness was the black wire however double check your stock pump to be sure, there's two different size connectors on the stock pump that will give away which one is positive and negative. I also recommend using marine heat shrink over the wire connections as it has a sealant inside that will provide extra piece of mind.
You can then install the center ring again if you removed it earlier, and remember to install the pickup tube filter before slapping it back in the tank! That about wraps it up with this DIY, follow the parts of the guide linked above for further instruction on re-installation.
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