I have a 91 245 that has 148k. I had to replace the fuel pump recently and now was thinking that I should do the intake pump as preventitive based on main fuel pump going out and the 148k. I will order parts from fcgroton which is across the country from me so I want to have everything I will need there. Question is what all should I plan on needing and should I replace the sending unit at that time or anything else while in there?

thanks in advance for help on this, lenny

I also recommend a new sending unit and bung nut. My gasket was fine. You can always return them if need be...

If you prefer to not buy the IPD tool, a brass punch is also a safe alternative - NO SPARKS!!!

My disclaimer:
I do not advice using this method, this is simply how I did it...a large hammer, large screwdriver and a rag to cover the screwdriver and protect against sparks.

I recently did mine on a 90 240 wagon.
I would definately recommend a new sending unit to have on hand, along with the usual parts to replace, sock, hose that usually cracks, bung nut seal pump etc.

I would also recommend the bung nut tool that IPD sells. It works much easier that a screw driver or drift of some sort. The access is very limiting and it is well worth the money in my book.
I ended up going in twice because the fuel gauge stopped working on mine, which was part of the old sending unit.

I hate going in twice but the hidesight is invalueable.
Good luck and have plenty of PB on hand.
--
My .02, Chapster out

Usually the sending unit pipes and wiring harness corrode. Then the gas gauge doesn't work and gas starts to leak. In order to get a good look at the condition you need to remove the hinged plywood from the back then acces door. When I changed my Sedan's sending unit I left the orginal pump. Just changed fuel sock, gasket. Personnaly I think changing the sending unit makes more sense than changing the pump. Some of the aftermarket pumps are noisy. IPD has a good tip of checking the condition of the pump by measuring the current at the fuse box.
--
1990 240 Sdn 277K,tach,strut brace,turbo sway 1990 240 Wgn M47II 157K,tach,strut brace,poly bushings,IPD sways