Installing Fuel Pump - 2001 RXDI

[Kayne]

Hi -

I'm trying to re-install my fuel pump for 2001 RXDI and the fit is extremely tight, almost as if the pump is too tall for the tank, which of course it's not. In watching install videos on YouTube, it seems as if I am doing it correctly, but when I drop it in the tank, I have to push down on the pump pretty. hard to get it to sit on the bolts to a point that I can fit the screws on. If anyone has done this install and can help, I would appreciate it.

Kayne

 

[DeWet]

Just a thought but if you measure from the opening to the bottom of the tank and then take them pump, compress the springs and then measure you can compare.
Easier to see whats going on than trying inside the tank.

 

[Uncle_Tone]

Make sure the hole pattern on the pump is lined up with studs on the tank. Im pretty sure one of the studs is just a tad off so it can only go in one way. There should also be an arrow on both the pump and the tank that should be lined up. Once you have all that lined up you will have to compress the pump into the tank. Pretty sure thats y there is a spring inside the pump. Ive ben it before with another set of hands.... that always works best......

 

[WaarrEagle]

That may be normal. There is a spring built in to the DI pump assembly to account for minor height variations in the plastic fuel tanks. I would think some compression is fine (I dont recall mine needing much), but not excessive. How much are you seeing?

 

[Kayne]

Thanks everyone! I just started messing with it last night - weather is finally warming up here in Michigan. I did notice that certain positions for the pump seem to "fit better" than others, which seems to confirm with what Uncle_Tone is saying. I need to look closer tonight for the arrow.

WaarrEagle - there is just a little bit of tension; what made me pause was that I didn't recall any tension when I took the pump out. But I also can't say that I was paying much attention. I try again this week and report back.

 

[etemplet]

I just installed the pump on my DI. YOu can squirt some oil on a little grease on the pump nozzle where it goes into the rubber. That will help. That section should collapse easily when you push down on it to start the nuts and washers.

Here is the wrinkle. The gasket will only fit one way and the TAB points to the left side of the sk and it won't fit correctly if it is upside down. Check the alignment before you begin. NOW.... if you are putting the gasket on the fuel tank and not on the cartridge you can have problems. Install the gasket on the cartridge and hold it in place. You won't have any problems if you do that. The gasket fits INTO the cartridge flange.

Just a note, I'm restoring a 2002 RX DI right now so if you have any questions just ask. Everything should be fresh on my memory. Did you check/take readings on the sending unit? I always clean it off with a pencil eraser or lightly scuff with fine emery. Saves surprises. Good Luck !!

 

[Kayne]

I just installed the pump on my DI. YOu can squirt some oil on a little grease on the pump nozzle where it goes into the rubber. That will help. That section should collapse easily when you push down on it to start the nuts and washers.

Here is the wrinkle. The gasket will only fit one way and the TAB points to the left side of the sk and it won't fit correctly if it is upside down. Check the alignment before you begin. NOW.... if you are putting the gasket on the fuel tank and not on the cartridge you can have problems. Install the gasket on the cartridge and hold it in place. You won't have any problems if you do that. The gasket fits INTO the cartridge flange.

Just a note, I'm restoring a 2002 RX DI right now so if you have any questions just ask. Everything should be fresh on my memory. Did you check/take readings on the sending unit? I always clean it off with a pencil eraser or lightly scuff with fine emery. Saves surprises. Good Luck !!

Thanks! This really helps. I actually tried to put the gasket on first, I thought it would be easier, so that might be part of the issue. Also, I didn't know there are tab and a specific way the pump is supposed to go. From messing around, I got the impression that there is probably on one way it is supposed to go, but I will check when I get a chance to go out and work on it again, that is it aligned properly.

I'm sure I'll come back to you with more questions. I bought the ski a year ago and it ran okay up till about 40, then it would hesitate and not go faster. The second time I went out, it got worse and eventually kept dying. So replacing the fuel filters (which were really nasty) is the first thing I am doing to diagnose the problem. If you've ran into this issue, or have any ideas, I'd be game for hearing. I should mention it ran on the trailer, just not in the water.

 

[etemplet]

Yes the pump like the gasket has to go on a certain way. Basically the electrical connection faces the rear of the tank and the vent line connection is around 1 O'Clock. You'll get it pretty easy. Good Luck.

 

[etemplet]

Here ya go perhaps this will help some. This is an RX DI 2002.

 

[Kayne]

Sorry for the delay in updating...kids, man. Thanks, that's a huge help. I was just going to upload a picture of where I installed, but that's it. Appreciate the help.