How in the world could a Q45 fuel pump replacement take 5 hours?
For the complete Q45 fuel pump removal and replacement procedures, see
http://www.nicoclub.com/zerothread?id=6268
Basically the early model Q45 fuel pumps go slowly at around 100K
miles.
You can tell when its going bad as it begins to hum.
If you ever hear a Q45 fuel pump then you should replace it
IMMEDIATELY!
While the Q45 fuel pump is humming, its slowly frying the fpcu.
The fuel pump is about 250 dollars.
The fuel pump control unit costs much more.
If you just replace the fuel pump, the degraded fpcu will fry the new
pump.
You will be caught in a vicious cycle (about six months in duration).
When the fpcu finally goes, the Q45 stops dead in its tracks (well, it
rolls).
Therefore, think of the fuel pump and the fpcu as an integrated unit.
So part of any good Q45 fuel pump job consists of repairing the fpcu.
You can ONLY remove the early Q45 fuel pump & fpcu by removing the back
seat.
Yet you must access the fuel pump & components from the cargo area.
In the cargo area, remove the passenger siding near the antenna.
Test & replace the fuel pump relay (bolted next to the rear antenna).
The relay is the green one (not the blue relay as often reported).
From the cargo area, remove the siding in front of the fuel tank.
Follow the shop manual procedures for testing fuel pump & fpcu
operation.
Inspect all fuel lines and harness connections (replace if necessary).
Remove the brackets holding the fuel pump fuel lines in place.
From the back seat, you generally remove the rear seat belts.
Then remove the rear seat bench.
Remove the rear arm rest storage bin.
Remove the rear seat back.
Remove the rear third stop light.
Remove the rear sundeck.
Remove the rear package binnacle.
Scrape away the black sound proofing tar above the fpcu.
Remove the fuel pump control unit brackets and remove the fpcu.
Remove the cover to the fuel pump control unit taking static
precautions.
Check all wiring and electrical contacts on your electrical bench.
Most likely you'll need to solder supporting wires as shown on nico.
After adding support wires to the fpcu, test again on your bench.
Back in the cargo area position yourself on your side facing forward.
Remove the fuel pump out the hole left by the rear package binnacle.
Inspect the gas tank for rust or other contaminants.
If contaminated, drop the gas tank and flush or repair accordingly.
On your shop bench, remove all brackets, fittings, and hoses from the
fp.
Replace those brackets hoses and filters onto the new fuel pump.
Replace the fuel pump o ring in the Q45 gasoline tank.
Bolt the new fuel pump onto the tank (going in the same way it came
out).
Reassemble cargo & rear seat components in the reverse order of
assembly.
How long would it take you to do this Q45 fuel pump replacement
correctly?