Unfortunately, we do have to replace the fuel tank
in Project Blue Collar, because the baffle is completely
separated from the tank in our original.
Now we'll show you how to transfer everything
from your original tank to the new tank.
And luckily, these exact same steps
can be used even if you're replacing the fuel
pump, or the sending unit, on your existing tank.
All right.
We're going to start out by removing the fuel pump
assembly from the original tank.
Now you can use a small flat blade screwdriver,
and remove the plastic clip that holds on the supply jumper line
to the fuel pump assembly.
And then use your fuel line remover tool
to go ahead and move the fuel return line from the fuel pump
assembly.
Unplug your electrical connector,
remove the lock ring, then lift the fuel pump assembly
from the tank.
The sock was no longer attached to the bottom of the pump,
because the baffle had moved around so much it tore it off.
All right, with your fuel pump assembly removed from the tank,
you can go to your workbench, lay everything out,
to replace your fuel pump.
Now I wanted to point out the differences in the fuel pump
assembly that you might see.
On the fuel pump assembly that came out of Project Blue
Collar, you have the supply tube that comes all the way out,
and you have just a short piece of rubber hose
that connects to the pump.
The more common style is like this,
where the supply line come straight down.
And you use the S-type hose that comes with your fuel pump.
Now every fuel pump comes with this S-type hose.
If you have the short link, like we have here,
you just cut it down.
We're going to be going back in with BBK-1607 255 liter
per hour fuel pump.
It comes with all the hardware and wiring connections
you need to install it back in your Mustang.
Our fuel pump has already been replaced
at some point in its life, but the connectors on a stock fuel
pump, will look just like this.
Now to remove your fuel pump, you
want to remove the two fasteners on the side of the assembly.
That way you can gain access to the pump.
Remove the hose.
Remove the filter sock.
And remove the pump from the hanger.
All right, with the fuel pump removed from the fuel pump
assembly, we can go ahead and unhook
the electrical connection.
If your new fuel pump comes with a new electrical connector,
go ahead and cut the wires coming out
of the fuel pump assembly.
Grab your new electrical connector,
and the butt connector supplied with the fuel pump.
Cut the connector pig tail to length.
And use the supplied butt connectors
to attach it to the wiring on the fuel pump assembly.
Now you can plug-in your new fuel pump.
Remove the red protective cap off the bottom of the pump.
And remove the grey protective cap off the top of the pump.
Grab the small rubber insulator, and slide it
on to the pump inlet.
And then grab your S-hose, and if required, cut it to length.
Attach the hose to the fuel pump assembly.
Tighten it down with one of the supplied clamps.
Slide the fuel pump outlet into the other side of the hose.
And attach it with the other supplied clamp.
Put your fuel pump back into the assembly,
and reinstall the screws for the side of the assembly.
With the assembly completely tightened back down,
and the pump in place, you can attach your fuel pump strainer
sock.
All right, with your fuel pump assembly completely
put back together, you can go ahead
and fold the stock into the tank.
And then slide the pump assembly into place.
You can take a peek through the filler neck hole,
and make sure that the socket and pump find
their way into the baffle properly.
Slide the O-ring onto the fuel pump assembly,
in between the assembly and the tank.
Put your lock ring into place, and tap it into position.
To remove the sending unit from your fuel tank,
you want to start by unclipping the electrical connector.
Then tapping the lock ring to the unlocked position.
Then you can lift the sending unit out of the tank.
All right, we've got our new 5.0 Resto fuel tank
sending unit that fits '87 to '97 Mustang.
It comes with a new O-ring, and a new lock ring.
So whether you're going into your old tank, or a brand
new one, it has you covered.
Installation is simple.
All you got do is slide it down into the tank,
place your O-ring in the groove, and then lock your lock ring
down into place.
All right.
The last couple parts we need to remove from our old fuel tank
to transfer over the new one is the vapor valve and hose.
Possibly the seal.
If your seal's messed up, we have new ones on our website.
And the harness.
Now, both are easy to remove.
You just pop up the vapor valve out of place,
and you can remove the seal.
And then you can pry the little retainer
off the lip of the fuel tank that holds the harness on.
And then you can transfer them to the new tank.
All right.
To finish up the fuel tank before it's
ready to go back into the car, you
want to go ahead and install your vapor valve seal,
whether you're reusing the old one or putting in a new one.
Snap it into place, then you can snap the vapor valve and hose
into place.
Grab your new fuel neck filler seal, slide it in the tank.
And this is something you want to replace,
even if you're reusing your old tank.
Then grab your electrical harness.
Click the retainer onto the pinch weld to the tank.
Connect your sending unit.
And then connect your fuel pump.
Grab your two supply and return jumper hoses.
Snap the return hose onto its connector.
And then slide the supply hose onto its connector.
And lock it down into place with the plastic retainer
that was included with your new fuel pump.
All right.
On your original gas tank, you have a hole
where the filler neck support bolt would go.
On your new gas tank, you cannot drill that hole
because of where they put the pinch weld.
Now a quick solution is just to use a flat washer on the filler
neck support, and then you can slide it on the tank pinch
weld, and then just tighten the bolt down.
And that will at least give it the support it needs.
All right.
We've got our fuel tank completely put back together,
and ready to go into the car.
Completely optional step, transfer the insulator pads
from the original tank to the new one.
And definitely do not forget your 5.0 Resto filler neck
seal, vapor valve seal, and the filler neck to trunk floor
seal.
Now for more fuel system parts and install videos,
check out latemodelrestoration.com.