Fuel pump and gauge sender unit - removal and refitting

Fuel system: single-point injection models / Fuel pump and gauge sender unit - removal and refitting

Warning: Observe the
precautions in Section 1 before working on any component in the fuel system.

General information
1 The fuel lift pump and gauge sender unit are combined in one assembly, which is mounted inside the fuel tank. Access is via a hatch provided in the load space floor and its removal involves exposing the contents of the fuel tank to atmosphere.

Warning: Avoid direct contact skin contact with fuel - wear protective clothing and gloves when handling fuel system components. Ensure that the work area is well ventilated to prevent the build up of fuel vapour.

2 The line fuel pump is mounted on a bracket, at the front of the fuel tank, next to the fuel filter.

Lift pump and
fuel gauge sender assembly Removal
3 It is advisable to carry out this operation when the fuel tank is almost empty.

4 Refer to Section 9 and depressurise the fuel system.

5 Ensure that the vehicle is parked on a level surface, then disconnect the battery negative cable and position it away from the terminal.

6 Refer to Chapter 11 and pivot the rear seat cushion upwards and forwards.

7 Slacken and withdraw the access hatch screws and lift the hatch away from the floorpan (see illustration).

7.7 Remove the access hatch screws and lift the hatch away from the floorpan

8 Unplug the wiring harness connector from the pump/sender unit (see illustration).

7.8 Unplug the wiring harness connector from the pump/sender unit

9 Pad the area around the supply and return fuel hoses with rags to absorb any split fuel, then slacken the hose clips and remove them from the ports at the sender unit. Make a note of their order of connection to ensure correct refitting later; note that the fuel return hose is colour-coded blue (see illustration).

7.9 Fuel pump connections

1 Supply hose
2 Return hose

10 Grip the slotted outer ring and turn it anticlockwise to release the pump/sender unit from the fuel tank aperture.

11 Carefully manoeuvre the pump/sender unit out of the fuel tank, taking care to avoid damaging the float arm. Hold the unit above the level of the fuel in the tank until the excess fuel has drained out (see illustration). Recover the rubber seal.

7.11 Carefully manoeuvre the pump/sender unit out of the fuel tank

12 Remove the lift pump/sender unit from the vehicle and lay it on an absorbent card or rag, in a well ventilated area (see illustration).

Inspect the float at the end of the sender unit arm for punctures and fuel ingress - renew the unit if it appears damaged.

7.12 Fuel pump/gauge sender unit

1 Float and arm
2 Fuel pump
3 Sender unit track and wiper 4 Fuel return hose

13 Inspect the sender unit wiper and track: carefully clean off any dirt and debris that may have accumulated and look for breaks or corrosion on the track windings.

14 Inspect the rubber seal from the fuel tank aperture for signs of fatigue - renew it if necessary (see illustration).

7.14 Inspect the rubber seal from the fuel tank aperture for signs of fatigue - renew it if necessary

Refitting
15 Refit the sender unit by following the removal procedure in reverse, noting the following points:
a) Smear the tank aperture rubber seal with clean fuel before fitting it in position.

b) Reconnect the fuel supply and return hoses according to the notes made during removal.

Line fuel pump
Removal
16 The line fuel pump is mounted alongside the fuel accumulator, behind the fuel tank, at the rear of the vehicle. Access is from the underside of the vehicle (see illustration).

7.16 Line fuel pump and accumulator unit

1 Line fuel pump
2 Accumulator

17 Refer to Section 9 and depressurise the fuel system.

18 Park the vehicle on a level surface, apply the handbrake, select first gear (manual transmission) and chock the front roadwheels.

Raise the rear of the vehicle and support it securely on axle stands (see “Jacking and vehicle support”).

19 Slacken the hose clips and disconnect the fuel lines from either side of the pump. If the clips are of the crimp type, snip them off with cutters and replace them with equivalent size worm drive clips upon reconnection.

20 Prise off the metal retaining clip and lower the pump unit away from its mounting bracket. Disconnect the wiring harness at the connector.

Refitting
21 Refitting is reversal of removal.