Installation Instructions for 2004-2006 Pontiac GTO LPE High Flow Fuel Pump Upgrade Kit (LS1 & LS2 engine) PN: L710660504 1557 Winchester Road Decatur, Indiana 46733 260 724 2552 phone 260 724 8761 fax www.lingenfelter.
About the GTO Fuel System The 2004 to 2006 Pontiac GTO fuel system uses a method that is referred to as a “return side jet” to fill the fuel pump canister. This means the fuel from the fuel pressure regulator return is being used to create the high velocity jet that fills the pump canister (by inducing a high volume/low pressure flow). The pump itself, like most modern fuel systems, actually pumps the fuel out of the canister to the engine and the jet refills the canister.
PRIOR TO ANY DISASSEMBLY 1) Read ALL instructions before starting. 2) Run the fuel tank low- the lower the fuel level, the easier the install. 3) If your vehicle has a lot of miles on the stock fuel filter, you should consider changing the fuel filter at this time (part number listed below). 4) Allow the vehicle to sit for at least one hour prior to changing the fuel pump to allow the fuel pressure to bleed down and for the engine and exhaust to cool down.
1. Remove all items from trunk. Remove felt spare tire cover. 2. Remove plastic snap-tabs with fork tool or similar tool (7 total snaps.) 3. Remove felt gas-tank cover. 4. Use an E18 inverted torx socket to remove the bottom two fuel-tank cage retaining bolts. 5. Removing the E18 torx bolt. 6. Use a 13mm socket to remove the top two fuel-tank cage retaining bolts.
7. Remove the fuel-tank retaining cage. 8. Unplug the fuel pump wiring harness plug. 9. Remove the top two retaining strap bolts with a 13mm deep socket. 10. Remove the driver’s side plastic vanity cover under the hood. 11. Unscrew the plastic Schrader valve cover. 12. Place a rag underneath the valve & depress the stem with a small screwdriver to relieve fuel pressure. NOTE: Fuel will escape from the valve. Be sure to keep heat sources away from the area. Eye protection recommended.
13. Replace the Schrader valve cap and vanity cover. 14. Use a jack to lift the vehicle and place on jack stands at locations stated in the owner’s manual. 15. Disconnect the quick-disconnect fuel fittings on the bottom of the fuel-tank from underneath the vehicle (the large one must be simply squeezed but the smaller one has a tab on one side that must be pressed in that will allow the line to be disconnected). NOTE: Fuel will escape from the connection- take care to keep heat sources away from the area.
19. Remove the restraining straps from inside the trunk. 20. Remove the snap-tabs (2) from the passenger side trunk panel. Peel back the felt cover. 21. Open the gas cap. Remove the fillerneck mounting nuts with a 10mm deep socket. 22. Pull the filler neck into the trunk. 23. Push the tank towards the passenger compartment and lift the retaining strap anchors from the plastic locks in the tank. 24. Remove the fuel-tank from the vehicle.
25. Cut the shipping tie-strap from around the tank and the Oetiker clamp from around the filler neck tube on the tank side. NOTE: the shipping strap is only for shipping and need not be replaced once the tank is installed in the vehicle. 26. Pull back the rubber filler-tube covering hose and undo the snaps around the perimeter of the tank holding the fuel-tank cover in place. Remove the cover.
29. Using a brass or similar non-sparking flat-end punch and a hammer, gently tap the fuel-pump module retaining ring counterclockwise to release it, and remove (or use GM tool J45722 if available) 30. Pull the module halfway out and remove the fuel module outlet hose from under the top of the module. NOTE: Fuel will be present after removal- take care to keep heat sources away from the area. 31. While the module is still halfway out of the tank, disconnect the fuel-pump outlet hose from inside the tank.
33. Remove the electrical connections from the underside of the top of the module and from the top of the pump. 34. There are four plastic snap retainers around the top of the lower portion of the module. Unsnap these and remove the fuel canister from the bottom of the module. This is most easily done by unsnapping one at a time and gently separating the module from the canister near the clip, working around and repeating the process to keep previously unsnapped fasteners from reconnecting.
36. The fuel pump is held in place with two snap retainers. Use two small screwdrivers inserted into the top of the lower module to hold these away from the pump, and pull the pump out. There are two inspection ports near the top of the fuel canister that can be used to ensure proper placement of the screwdrivers and proper snap-retainer disengagement. The fuel pump sock may be removed from the pump by using a small screwdriver to remove the snap-ring if fuel pump removal is difficult. 37.
39. Module Modifications. For the fuel pump to sit properly in the module, some modifications need to be made. The three ribs inside the top part of the module, indicated by the screwdriver (shown in figure 1) must be cut back until they are above the small windows indicated by the pen in figure 2. Make sure that the ribs inside the fuel pump socket do not interfere with the new pump when it is installed.
41. Push the new fuel pump’s outlet neck into the modified module (the O-ring should hold the spacer in place). When the pump is fully seated the pump’s black electrical connector should be three-quarters the way up the small window, as shown in Figure 3. Make sure that the fuel pump is setting straight and not setting crooked. Figure 3 42.
45. Reinstall the black plastic fuel level bracket and fuel level float arm. 46. Replace the module O-ring seal with the new supplied seal & place the module halfway back into the tank. Reconnect the fuel-pump outlet and fuel module outlet hoses. 47. Place the module back into the tank, making sure that the outlet faces the filler neck and the plastic tab on the module fits between two mounting tabs. 48.
50. Reinstall the black plastic cover, making sure the connecting snap-tabs snap back into place. 51. Slide the rubber hose back in place and use the included hose-clamp in place of the Oetiker clamp that was previously removed. 52. Place the fuel-tank back into the trunk, pushing it as far back as it will go. 53. Push the restraining strap anchors back down, and pull the tank forward to lock them in place. 54. Push the filler neck end back through into the fuel-filler recess.
56. Replace the quick-disconnect fuel lines. 57. Replace the plastic differential speed sensor wires. 58. Plug the fuel-pump harness connector back in. 59. Replace the retaining straps. The top two bolts (13 mm socket) should be torqued to 15 ft-lbs and the bottom two nuts (17 mm deep socket) should be torqued to 30 ft-lbs. 60. Replace the plastic rear cover and bolts using a 17mm socket and torque to 15 ft-lbs.
61. Replace the fuel-tank retaining cage. 62. Replace the four bolts (top 13mm socket and bottom E18 inverted torx socket) and torque all to 15 ft-lbs. 63. Installing & torquing to 15 ft-lbs. 64. Replace the felt spare tire cover. 65. Add fuel back to the fuel tank. 66. Start the vehicle. Check to make sure the vehicle is running properly and all of the fuel line connections are connected properly and you do not have any leaks.
The fuel flow of this pump kit can be further enhanced with the use of a fuel pump voltage boosting device like the Kenne Bell Boost-a-Pump. The Boost-A-Pump is available through Lingenfelter Performance Engineering. The normal and boosted output of the pump is shown in the following table (Table 1). Table 1 Pump voltage Pump Vdc Stock GTO 12.0 Stock GTO 13.5 GSS340 12.0 GSS340 13.5 GSS340 16.0 GSS340 17.
