Pump - fuel - ’k’ series

Refit

WARNING: During assembly, ensure that all electrical connections are made correctly. Earth tag on fuel pump negative terminal must not become distorted.

1. Position spacers to inlet & outlet ports. Lubricate NEW ’O’ ring seals with silicone grease and fit to ports.

NOTE: Early fuel pump assemblies did not have an earthing spring fitted to the fuel pressure regulator. If fitted, ensure spring is correctly located.

2. Carefully fit filter to ports and push fully home, ensuring that sprag clips engage fully.

WARNING: Ensure that the filter earthing tag is correctly located to contact the base of the fuel filter.

3. Position spring to filter recess and engage in top location.
4. Engage pump top to base, ensuring that slots engage correctly with lugs.
5. Fit fuel gauge sender unit. See INSTRUMENTS, Repairs.
6. Connect battery earth lead.

PUMP - FUEL - ’K’ SERIES

Service repair no - 19.45.08

WARNING: Fuel pressure of up to 3.5 bar will be present in the system, even if the engine has not been run for some time. Always depressurise the system before disconnecting any components in the fuel feed line (between the fuel pump and the fuel rail). The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion. See ENGINE MANAGEMENT SYSTEM - MEMS, Information.

NOTE: The fuel pump is an integral part of the fuel pump housing and cannot be renewed separately.

Remove

1. Disconnect battery earth lead.
2. Open tail door and fold rear seat forward.
3. Raise luggage and passenger compartment carpets for access to panel.

4. Remove 6 screws securing access panel.
5. Remove access panel.
6. Disconnect multiplug from fuel pump and run engine to release fuel line pressure.
7. Disconnect battery earth lead.
8. Disconnect fuel hose from fuel pump.

CAUTION: Plug the connections.