Low Pressure Fuel Pump Access Hatch

As I mentioned in an earlier article my '88 dies when the tanks is about half full.  If you top it off with some additional gas it starts up and runs fine.

From my research it appears this specific issue is due to the low pressure fuel pump inlet getting clogged.  As you can imagine a 25+ year old vehicle's fuel tank probably has some gunk in it.

Your first option is to drop the fuel tank but for my Bronco which I take 4-wheeling mostly I wanted a quick way to fix a potential problem should it occur.

My solution was to drill an access hole above the fuel tank inside the cab.

 

 

As you can see from the picture above I added some hinges that were riveted in to easily open and close the hatch.  I'm going to add some weather stripping and a latch to help keep it closed.

 

Note: You DON'T want to puncture the fuel tank so you need to be extremely careful.  I used a jig saw on blocks of wood to ensure it wouldn't pierce the tank or spark.  Don't use an angle grinder because it will throw sparks.

 

Step 1:  Remove the Phillips screws holding the metal trim piece at back of the cargo area.

 

Step 2: Carpet will pull up.  I had some pieces laying under there that were old nasty wood pieces to help level the back and I threw them away.

 

Step 3: Measure for the tank.  I recommend going under the body and using either a long drill bit or some type of puncture tool to mark the boundaries of your hole.  Then gently drill holes so you can use the jig saw.  Remember: Lift the jig saw so it won't go all the want down and hit the top of the tank.  Also make sure your cutting path doesn't cut any fuel lines or wires.

 

Step 4:  Take a grinding wheel or something to smooth the edges of the access panel.  Apply weather stripping or other material to make form a good seal.  Consider hinges and a latch mechanism to keep the hatch closed and from rattling.

 

Step 5: Replace carpet and install trim piece.

 

There is a post at Full Size Bronco someone else did that is a similar hatch and has some measurements if you want to use them versus your own: http://www.fullsizebronco.com/forum/showpost.php?p=2238881

 

Note:  Fuel pump screws off and you'll want to use a shop vac or something to clean the area so you don't contaminate the fuel tank.