In tank fuel pump replacement

[brandon666]

Have just replaced complete fuel pump and sender unit on my diesel 75. Just wanted to share my experiences with anyone else similarly inept in mechanical things. After following the excellent guides elsewhere here I anticipated a few hours and headaches but it took less than an hour including looking for misplaced tools
This was largely a result of my biting the bullet and paying for a complete pump/ sender unit (£175) rather than attempting the rebuilding and replacement of the pump unit and a potential ££ saving. In part this was because the car was parked where it died, well away from my home on a busy street!
After pinning back seats and removing access panel my first challenge was the removal of the two fuel lines. One is held in place with a simple clip and pulls off easily, second one was a puzzle until I realised all I need do is depress the little 'button' at the foot of the connector that fits onto the pump. The electrical connector pulls of after the cover is slid toward the front of the car. Removal was easy, after preparing for diesel spills simply loosen locking ring with screwdriver and mallet then remove.Pump can then be extracted with a little gentle maneuovering (the rubber seal is taken off to make this easier). Undoing the fuel pipe in the tank was simple and uses the same ' push button' connection as earlier described and the electrical connector releases with a squeeze. Replacement was pretty easy, ensuring the components were replaced in same alignment that they were removed. Replacing seal, locking cap and two external pipes was a reversal of removal. When wiring and battery were re connected I primed the system with two 50 second bursts of power at ignition setting two and closed my eyes.First click and she started, running smoother than ever before.
A big thank you for the many detailed diagnosis and technical guidance freely offered here. Saved me ££££'s and I feel confident to carry on driving (until the next visit)

[Arctic]

Hi John.
Great place this isn't it to learn and in your case give you the confidence to tackle a job most fear, thank you for posting up I am sure it will spur on others to take the plunge to tackle jobs

[Royster]

Yes, well done mate.

I took the replacement pump only route and it took a fair while.
If I didn't have a company van I would have done the same as you.

Don't throw the old unit away. Someone could use it and replace their pump pre diving into the tank

If you get a diesel leak later on, it will be the gasket. They are about £10 and can be replaced with the unit in place

Royster

[mbev51]

can you just tell me which gasket you are referring too, is it the large one under the screw on top?

[Royster]

Evening

Its the top one just under the rear seat. Mine suffered a kink allowing the diesel fuel to escape and drain down the outside of the tank

Rimmers sell them for £6.25

Fuel Pump Seal - Pump to Tank - Petrol & Diesel - Aftermarket




Part No.: ESR3806P





Royster

[DMGRS]

Just had to re-seat this on my latest ZT - recently had an in tank pump, and a bit of diesel smell with a full tank!

Was going to change it, but it's evidently new - so after being re-seated it was fine.
For reference, we have the original gaskets here: 75/ZT Fuel Tank Seal ESR3806

[Kennyeth]

Very well done, gold star of the week
My pumps are gone on both cars, what`s always puzzled me are the pipe clamps, those that need a special tool to put in place
By replacing the whole pump new, would there be no need to touch those clamps ?
Ken.

[Yam]

Well done ace.
Did both of mine last August, and the helpful guides in here made it relatively painless.
Hardest part for me was relocating the complete assembly because you can't see.....
The seats where a pig to relocate on their hooks as well.
The 'how too....' guides and help on here are amongst the best on any car forum I've ever been involved with.

[lesron]

Under took this job sunday
first off went to the local boot fair purchased 6 old screwdrivers and an old bair dryer
New pump had arrived off ebay
Found it easier to reach under seat and pull the rear seat braket down and push back.
No problems getting pump housing out
As stated above the two pipes both have 2 types of clips
wasn't looking forward to cutting pipes as had been surgested
Managed to seperate two halfs with 3 drivers carefully ,swaped pump
Had to use two cable ties to secure in tank fuel pipw on to pump,
I found the difficulty came with getting the pump back in due to the platice and pipe work thats in the tank possibly being in the way , managed to use a screwdriver to move it hopefully out the way
I also found i had to place the rubber internal V grove gasket into the one in the tank then gentle slide the plastic pump housing through it.
All seams ok back up and running havent filled it up to ensure fuel gague works as its not insured for the road at present.