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.

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