Fuel pump - removal and refitting

Note: Refer to the precautions at the end of Section 1 before proceeding.

Removal
1 The fuel pump is bolted to the underside of the car just to the rear of the fuel tank. For access raise and support the car securely at the rear.

2 Disconnect the battery earth lead.

3 On the K-Jetronic system relieve the system pressure by slowly loosening the fuel feed pipe union at the warm-up regulator (see illustration). Absorb the fuel leakage in a cloth.

6.3 Warm-up regulator fuel feed pipe (A), outlet pipe (B) and wiring
6.3 Warm-up regulator fuel feed pipe (A), outlet pipe (B) and wiring multi-plug (C)

4 On the KE-Jetronic system relieve the system pressure by slowly loosening the cold start valve union on the top of the fuel distributor (see illustration). Absorb fuel leakage in a cloth.

6.4 KE-Jetronic system cold start valve pipe union (arrowed) on fuel
6.4 KE-Jetronic system cold start valve pipe union (arrowed) on fuel distributor

5 Clamp the fuel inlet hose midway between the tank and the pump using a brake hose clamp, self-locking grips or similar. If the fuel level in the tank is low you may prefer to drain the fuel from the tank into a suitable container once the inlet hose is disconnected.

6 Disconnect the fuel inlet and outlet pipes from the pump, catching fuel spillage in a suitable container (see illustration). Once disconnected do not allow dirt to enter the pipes, temporarily plug or seal them if necessary.

6.6 Fuel pump outlet pipe (A), electrical connections (B) and pump bracket
6.6 Fuel pump outlet pipe (A), electrical connections (B) and pump bracket retaining bolt (C)

7 Note the electrical connections to the pump and disconnect them.

8 Loosen the pump bracket retaining bolt and then withdraw the pump unit with rubber protector sleeve.

Refitting
9 Refitting of the fuel pump is a reversal of the removal procedure. Renew the feed pipe from the tank if it is damaged or defective.

10 Check that the rubber protector sleeve is correctly positioned round the pump before tightening the clamp nut.

11 On completion, tighten the warm-up regulator or cold start valve fuel unions, reconnect the battery earth lead, start the engine and check for any fuel leaks.

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