The fuel pump assembly is in place and ready to be wired up. I originally planned an external pump like the factory but saw that there were some Subaru swaps installing an Impreza metal pump assembly to the 914 tank. I felt like this was a more elegant solution and packaging wise would be perfect.
I found a used pump assembly with unknown new fuel pump installed for $39. It had a feed and return line but no vent. That's fine by me since the stock tank already has a vent setup anyway. It also had a very large in tank fuel filter assembly. I couldn't easily install the pump with this attached so I finally decided to ditch it.
First I pulled the rubber gasket off of the flange to use as a template. The tricky part of this install is the sump positioning. Luckily there are a handful of pics out there to guide me.
This ends up deleting the 914 fuel level sender. Some folks drill a new hole and move it elsewhere but I'm going to use the Subaru one to send a signal to my dash.
Here's a new hole.
At this point I tried installing the pump with the massive in tank filter but it wasn't fitting through easily nor dropping into the sump easily. I decided to remove it from the equation. I may trim the opening a bit more for this as I do see a major benefit to having a filter here. It's also super easy to access this pump assembly for maintenance compared to in the engine bay or elsewhere.
With that removed I started working on getting the pump right in the middle of the sump. When I first installed it, the sock was pressing against the rear of the sump lip. After a half dozen in and out test fits, I bent the bracket enough. You can see the bend I placed right where the wiring plugs into the pump.
After that I tied a string to the float to check range of motion. That too wasn't going to work so I slowly tweaked it until it had plenty of clearance to function as intended.
With the float sorted I marked new holes to drill for nutserts. I'm glad I didn't drill based on the rubber seal I initially traced as it would have been terrible for alignment and flatness. The first hole I drilled landed through what was left of the sender flange. It had a small seam weld holding on so I drilled the hole nearest to it first. Out it came with a little wiggling.
The surface isn't the flattest, so I spent some time with a hammer and dolly doing my best to level it all out. Then it was time for nutserts. This is my first time using the tool and it's a game changer. I'll need to order some more m6 already since the kit is pretty light on quantity for each size. I imagine that will be one of the most common sizes I'll use.
Now for test fitting.
LIKE A GLOVE!
I may consider getting a different sock but this one lands at the perfect depth based on my measurements. The return line dumps directly into the sump as well which should keep plenty of fuel exactly where it's needed.
The filler cap still fits.
I clearanced the lip of the tank a smidge for the supply line.
For now I looped the old supply and return line. I'm not sure if this is the permanent decision as it may not package well. I'd prefer to find a nut to cap both off but based on my searches have come up empty handed. Pretty sure it's a very fine thread m17 but it's been a few days since I last looked. I'm also now realizing that what I thought was a return line is in fact a vent line. I may use the stock return and cap off the vent on top. Hmmmmm.
All in all I'm stoked everything came together the way it did. The rubber flange seal looks to be flat all the way around when tightened down. Since the nutserts are above the edge of the tank I may cut a gasket out that fills up that space for a better seal.
