I've done the fuelpump replacement on rx8 's several times. It's always been a simple job, but after recently going in to have all my recall work done something is different. The story goes.... I had the recall work done and i asked the guy running the show if they took out my high flow fuel pump and he didnt know....no one wanted to talk to me about it so i assumed they did. I got home and removed the fuelpump and sure enough I had a brand new fuel pump. My DW200 was over a year old so i wasn't really upset... I just cant get the dang lock ring to thread back on. I can kinda push down on it and it'll "snap" down on the first threads, but it won't turn a mm by hand. I have to beat it with a screwdriver and pliers to get it to move at all and it wont get tight enough to make a seal. I tried driving it after tightening as much as i could ,but i had all kinds of fuel pressure issues. The car ran like doo doo.... Am I missing something? Is there something that can go wrong with the threads ???

 

I swapped in a DW200 as well and didn't have an issue. Yes, the dealerships swap the entire assembly along with the embedded fuel pump. The threads of the lid... being plastic... c/b damaged. Not sure you'll get much love from the dealership...given you took it off. I'd inspect the threads...and if damaged, purchase a new lid, ~$50.

 

yes, they could have damaged the threads if it was installed cross threaded. I believe the threaded piece on the tank may be replaceable too. The lid/leaking issue has nothing to do with how the car runs or fuel pump operates though. That’s a separate issue. Aftermarket pump on an S1 module requires modifications to install and have it work properly. Sounds like you need to open it up and assess the situation regardless. There’s a significant fire hazard with it leaking so please be mindful of that and it being not far from the driver position too.