Contents: Removal ↡ Installation ↡
Removal
Warning: Before working on any part of the power supply system, read the safety precautions in paragraph 1.
1. The fuel pump is located underneath the floor hatch at the rear of the vehicle next to the fuel filter.
2. Contact paragraph 2 and depressurize the power supply system.
3. Disconnect the negative battery terminal.
4. With the vehicle on a level surface, apply the parking brake and place chocks under the front wheels. Jack up the rear of the vehicle and place it on supports (see Fig. "Lifting the car and placing it on supports").
5. Loosen the screws or unfasten the fasteners and remove the shield from the fuel pump, filter and battery (see Fig. 4.5, a-c).
Fig. 4.5, a. Unfasten the fasteners...
Fig. 4.5, b....and remove the shield from the fuel pump, filter and battery
Fig. 4.5, c. Gasoline filter (A), pump (B) and battery (C)
6. Disconnect the fuel pump wire connectors from the connector block (see fig. 4.6). Label each connector well to avoid confusion during installation.
Fig. 4.6. Bypass bolt (A) and electrical connectors (B)
7. Using suitable hose clamps, clamp the flexible fuel supply hose to the fuel pump and the inlet pipe from the filter. Do not use a vice as this may cause internal damage to the hoses.
Warning: Do not pinch the hose at a bend, as this may cause it to deteriorate, resulting in fuel leaks. Only pinch the hoses at straight sections.
Homemade device
If you don't have hose clamps, fit two 13mm sockets on top of the jaws of a pair of vices and use them to squeeze the hose. The round surfaces of the sockets will protect the hose from being crushed.
8. Loosen the nipples and disconnect the fuel lines from the rear of the fuel pump. Where bypass bolts are used, remove the sealing washers and destroy them - new ones are required when installing. Be prepared for some gasoline to spill - place a container under the pump and cover the surrounding surfaces with rags.
9. Loosen and remove the screws, loosen the mounting belt and remove the pump from the support bracket (see fig. 4.9).
Fig. 4.9. To loosen the filter mounting clamp, unscrew the screws
10. If the mounting bracket cannot be lowered sufficiently to remove the pump, where provided, remove the bypass bolts and disconnect the fuel line from the pump accumulator and filter. Again, be prepared for some fuel to spill and remove the sealing washers. Once the fuel line is disconnected, the fuel pump will be able to be lowered.
Installation
11. Installation is carried out in reverse order. Please note the following points:
- a) Where provided, check that the anti-corrosion plastic gasket is installed correctly to prevent metal-to-metal contact between the pump and the clamp.
- b) When connecting the bypass bolts, install new sealing washers.
12. When finished, start the engine and check that there are no leaks around the removed parts. Note that air has entered the fuel system and it may take longer than usual for the engine to start.