DeatschWerks DW65a User manual

DeatschWerks
97-06 Commodore DW65a Fuel Pump Installation Guide
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9-653-1011
97-06 Commodore DW65a Fuel Pump
Installation Guide
Parts List:
DW65c, 9-651
Fuel Sock
3-116 O-Rings (x2)
Fuel Sock Retainer Clip
Super Lube

DeatschWerks
97-06 Commodore DW65a Fuel Pump Installation Guide
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GenIII Commodore DW65a Fuel Pump Install
PLEASE READ –this guide is intended to aid in the installation of our products. It is recommended that
factory manuals or instructions are followed to remove the fuel pump assembly from the vehicle. Some
instructions in this guide are generic. The factory manual should supersede any contradiction.
This kit uses PTFE tubing and permanent clamps. Heat from a heat gun, high temperature hair dryer, or
boiling water may be used to soften the tubing ends to make installation onto the pump and assembly
easier. DO NOT USE AN OPEN FLAME! The permanent clamps may be crimped with end cutters or side
cutters. PTFE tubing installation video: https://www.youtube.com/watch?v=6NE6tRE1Kug
Below is a picture of suggested tools that will make the installation process easier.

DeatschWerks
97-06 Commodore DW65a Fuel Pump Installation Guide
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1 –disconnect the main connector for the fuel level sender and fuel pump electrical connector
2 –carefully remove the tube connecting the fuel pump the fuel pump assembly, by cutting it with a sharp
knife

DeatschWerks
97-06 Commodore DW65a Fuel Pump Installation Guide
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3 –disconnect the fuel pressure regulator (green) by prying it up and out of the pump assembly, then pull
the top of the assembly from the bottom using a similar motion as a slide hammer

DeatschWerks
97-06 Commodore DW65a Fuel Pump Installation Guide
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4 –remove the center assembly from the lower assembly by depressing the 3 tabs (green) and pull up on
the center assembly, away from the lower assembly
5 –remove the OE fuel pump by squeezing the tabs and pulling the pump away from the center assembly

DeatschWerks
97-06 Commodore DW65a Fuel Pump Installation Guide
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6 –prep the DW65a for installation
7 –install the DW65a into the center assembly by clicking the tabs on the fuel sock into place and then
reinstall the center assembly into the lower assembly

DeatschWerks
97-06 Commodore DW65a Fuel Pump Installation Guide
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8 –install the DW convoluted tubing to the outlet of the DW65a and secure the hose clamp
9 –connect the convoluted tubing to the upper assembly and secure with the hose clamp, then reinstall
the top assembly to the lower assembly
10 –reinstall the assembly into the fuel tank, then crank the engine for a period of time long enough to
prime the pump assembly and evacuate the air introduced during the pump installation process
11 –attach supply line to the outlet of the pump assembly