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Just finished doing it myself on a VS Series I station wagon.
OK, it's better to use a car hoist to do this, but who has one of those at home - my instructions will be using a jack and a car stand. Make sure the car is securely propped up before you work on it - you will be working under the wheel arch, and their won't be much left of you if the jack fails. USE A CAR STAND!
The fuel pump for the VS Commodore is in the fuel tank - to the front drivers side of the fuel tank. So prior to doing following these instructions, you should drain the fuel tank of as much fuel as you can. Petrol is explosive, so make sure you work in a well ventilated area (outside) and don't smoke.
Tools you will need:
- 7mm socket
- small pair of pliers
- a bucket for petrol
- flat head screwdriver
- Replacement fuel pump kit
- Eye protection
1. Park your car somewhere flat. (EDIT): Remove fuel pump relay from the engine bay and start the car. It will cut out pretty quick. If the pump is not functional at all, you can still run down the fuel pressure by cranking the engine with the fuel pump relay removed. Doing this will help stop fuel from blowing in your face when you remove the fuel lines from the tank...
2. IMPORTANT - Open the bonnet and pull both leads off the battery. We don't want any electrical sparks when working on the fuel tank.
3. Jack the rear drivers side of the car up, enough to allow you to remove the wheel, and maybe a little higher.
4. Prop the car in position with a car stand and take the rear drivers side wheel off.
5. On the front of the fuel tank is a small round panel with one electrical connector and 2 fuel lines attached. Take note of which way the fuel lines poke out of the panel. It will have to back the same way.
6. Unplug the electrical connector.
7. Put on your eye protection - there may be pressure in the line and the next step will release this pressure, spraying a bit of fuel around.
8. Using a flat head screwdriver disconnect the fuel lines. Keep your bucket handy, if there is any fuel in the tank, it will come out the lines.
9. Unscrew the 5 screws holding in the panel. start from the bottom of the panel. Keep your bucket handy again, the holes the screw goes into will leak petrol. Wait until the petrol stops flowing out the screw holes.
10. Now the hardest bit. The pump assemply is long and has lots of bits hanging off it. Start by pulling it out until you can see the black fuel line held on by a clip. Tie some wire around this fuel line (to keep it from falling back into the tank) and remove the clip with a pair of pliers.
11. Pull the assembly out. It's long and will need some manouvering. Watch out for the fuel float which is attached to the assembly, don't knock it around too much.
12. Follow the instructions that came with your new fuel pump and replace the pump in the assembly.
13. Put the assembly back in the fuel tank using a new gasket. Being careful of the float and make sure the pipes on the outside are in their origianl position. Use thread lock on the panel bolts and don't screw them in too hard. Just hard enough to mould the new gasket into place.
14. Reconnect the fuel lines and electrical plug
15. Put the wheel back on and remove the car stands and jack.
16. Put some fuel in the tank.
17. Reconnect the battery.
18. Put the key in the ignition and turn the car 'on' (don't start it yet) Let the fuel pump run to prime the car.
19. Start the car!
What else can I help you with?
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