Fuel pump (2.0 litre SOHC) - removal and refitting

Caution: Refer to the precautions in Section 1 before proceeding.

Removal
1 The fuel pump is located under the rear of the vehicle next to the fuel tank (see illustration).

8.1 Fuel pump location
8.1 Fuel pump location

A Inlet hose
B Outlet hose
C Electrical feed
D Flow damper

2 Disconnect the battery negative lead.

3 Chock the front wheels, then jack up the rear of the vehicle and support on axle stands (see “Jacking and Vehicle Support”).

4 Clean the area around the pump mounting, and position a suitable container under the pump.

5 Using a hose clamping tool or self-locking pliers, clamp the fuel tank-to-pump hose to prevent excessive petrol spillage, or alternatively make arrangements to collect the contents of the fuel tank which will otherwise be released. Disconnect the hose from the pump.

6 Slowly loosen the fuel flow damper fitted to the pump outlet union, to relieve the pressure in the fuel line, then remove the damper and disconnect the outlet pipe from the pump.

Plug the end of the pipe to prevent excessive petrol spillage.

7 Disconnect the wiring plug(s), then slacken the clamp bolt and slide the pump from the bracket assembly.

Refitting
8 Refitting is a reversal of removal, noting the following.

9 When refitting the flow damper to the pump ensure that the pump outlet pipe is correctly routed (see illustration). It is possible to inadvertently rotate the banjo union through 180º, which routes the outlet pipe too close to the exhaust.

8.9 Correct and incorrect routing of fuel pump outlet pipe
8.9 Correct and incorrect routing of fuel pump outlet pipe

A Fuel pump
B Outlet pipe
C Exhaust pipe
X = 30.0 mm (1.2 in)
Y = 100.0 mm (3.9 in)

10 After refitting and securing the pump, but before lowering the vehicle, reconnect the battery and switch the ignition on and off several times to pressurise the fuel system.

Check for leaks around the pump; if all is satisfactory, switch off the ignition and lower the vehicle.

Fuel pump/fuel level sender unit (2.0 litre DOHC/1.6 & 1.8 litre (R6A type) CVH) - removal and refitting

Caution: Refer to the precautions in Section 1 before proceeding.

1 Remove the fuel tank.

2 Unscrew the fuel pump/fuel level sender unit by engaging two crossed screwdrivers in the slots on either side of the unit mounting flange. Recover the seal.

3 Refitting is a reversal of removal but fit a new seal.

Fuel tank - removal and refitting

Refer to Chapter 4 Part A, Section 9.

Fuel level sender unit (2.0 litre SOHC) - removal and refitting

Refer to Chapter 4 Part A, Section 10.

Idle speed and mixture - adjustment

Refer to Chapter 1, Sections 15 and 16.

    See also:

    Pistons and connecting rods - removal and refitting
    Removal 1 Remove the sump and the cylinder head. 2 Check the big-end bearing caps for identification marks and if necessary use a centre-punch to identify the caps and corresponding connecting ro ...

    Exhaust manifold - removal and refitting
    Removal 1 Disconnect the battery negative lead. 2 Remove the air cleaner and pull the hot air pick-up pipe from the exhaust manifold hot air shroud. 3 Remove the securing screws (1 screw on DOHC ...

    Major operations requiring engine removal
    The following work can only be carried out after removal of the engine from the car: a) Crankshaft main bearings - renewal . b) Crankshaft - removal and refitting. c) Flywheel - removal and refitt ...