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Fuel pump replacement for beginners

6.3K views 2 replies 3 participants last post by  dnkifreak  
#1 · (Edited)
Pump replacement info is readily available but most seem to miss some practical tips for the apparently easy stuff. Here, I have included the areas I had problems with.

The example is based on my MY2001 3.0 V6 Petrol S-type and a replacement Airtex E2314 pump. Airtex has a video detailing the pump replacement into the module:


My problem
No-start condition.
Engine turns but doesn't fire up. Attempts to start the first time when some fuel in the line but afterwards there appears to be no burning of fuel.
Turn key to position 1 and pump is silent. No priming audible.

From the Workshop manual:

P1233, P1235, -Fuel Pump Primary Circuit Failure
Possible Source(s):
  • Damaged relay.
  • Damaged harness.
  • Connector loose or corroded.
  • Connector pins(s) bent or tracking between connections.
  • Damaged ground.
  • 'Popped' inertia switch.
Check the ground supply to the fuel pump
1. Switch the ignition to the OFF position.
2. Measure the resistance between the fuel pump electrical connector FP4 pin 3, (BR) and ground.
If the resistance is less than 0.5 Ohms install a new pump.

To install a new pump:

1. TIP! To maximize access, move the seat bases and backs as far forwards as they go.

2. Disconnect the battery.

3. The fuel pump is submersed in the fuel tank and can be accessed from under the the rear seat on the RHS of the car. UK driver's side.

To remove the seat, pull on the latches and lift he seat base.

Seat_Base_Latch.jpg


4. Undo the seat belt anchor to allow the seat base to be completely removed.

Middle_Seatbelt_Anchor.jpg


5. Pull back the insulating material. It is not necessary to remove the trim around the door. Just make sure you don't drip fuel when removing the pump unit!!!

Door_Trim.jpg


6. Remove the black plastic cover. These are very stiff and difficult to lever out. However, levering them in halfway actually makes it easy to gently twist them out.

Seat_Base_Latch_Pump_Cover_RHS.jpg


7. Disconnect the electrical connector.

8. Release the two pipes. Simultaneously press in the two tabs and pull the pipe from the connector.

TIP! You might need to push down first to release and you might have to press the release tabs a number of times as the pipe catches on the next locating point.

If the connectors are no longer operational, an alternative approch is well documented here: No Fuel Pressure - Jaguar Forums - Jaguar Enthusiasts Forum

Pump_Module_Connections.jpg


9. Remove the pump module locking ring (light blue in the photo) using a tank cover removal tool if you have one or by carefully tapping the ribs with a piece of soft wood and a small heavy hammer/mallet.
Place the wood against a long side of a rib (my preference was to use a side rib as it totally in line with the threads and is how the official tool works) and tap gently, using only as much force as required. Modifying the area of wood that contacts the rib to maximize spreading the load is worth the extra effort, even though the plastic appears to be strong and the collar came free quite easily.

RHS_Tank_Connections.jpg


10. Extract the pump module. First lift the top plate and extend the piping sufficiently to reach in and release the locating clips.

Pump_Module_Assembledjpg.jpg


11. Slowly and carefully lift out the pump module, ensuring that the filter and the level float do not get caught and damaged. Let as much fuel drip back into the tank as you can and then lift out into a petrol resistant tray.

12. Undo the electrical connector from the pump motor.

13. Undo the three small screws from the top of the pump module housing.

14. Lift out the damaged pump motor.

Make sure that the small non-return valve stays in place in the housing inner cover. If it falls out, replace it round-hole end up.

Image


15. Clean the pump module of any deposits.

16. Replace with the new pump motor using any seals, accessories and filters provided.

17. Replace the housing inner cover, ensuring that the NRV is still correctly located inside the vent.

Image


18. Carefully, relocate the pump module in the tank and click both latches into place.

19. Place the outer cover back in place making sure that the locating tabs are correctly aligned.

20. Replace the pump module locking ring and tighten by hand to make sure that it isn't cross threaded. Tighten with the appropriate tool.

21. Reconnect the two pipes and the electrical connector.

22. Reconnect the battery.

23. Prime the system a few times with the key to position 1. When the priming noise is stable, attempt to start the engine.

24. If the car runs, replace covers, insulation, seat belts and seat base.
 

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