90q fuel pump questions

[quk@isham-research.demon.co.uk (Phil Payne)]

In message <l0302090bb1a1e99536e0@[194.134.63.118]> Tom Nas writes:

> One item certainly looks like a pump- it has two electrical connections and
> is connected to the fuel line- or at least to a rather thick rubber hose
> leading to the tank. It's about 5in long.

Order replacement fuel pump mounting bushes.  At least one _will_ be
defective.  You will also need two new crush washers for the banjo
bolt in the end of the check valve.

Disconnect the battery.

Apply a clamp to the thick hose from the tank so as to seal it
completely.

Disconnect the hose from the pump.  BEFORE PROCEEDING CHECK THAT THE
OLD HOSE FITS THE NEW PUMP.  If not - refit, unclamp, and start finding
the right size of hose for the new pump.  If you have to change the
hose, the process includes completely draining the tank.

Assuming the car's old hose fits the new pump:

Disconnect the main fuel line that goes forward from the whole
subassembly.

Disconnect the power connections.

Undo the bolts and screws holding all three components to the bottom of
the car, and remove the whole contraption to a bench.

The outlet from the fuel pump is in two parts - a check valve screwed
into the pump, and a banjo fitting bolted into the end of the check
valve.  _ALL_ attempts to unbolt the banjo fitting _ALWAYS_ result in
the check valve coming away from the pump instead - unfortunately, this
leaves you with a dilemma.  You can just destroy the electrical
terminals and wind out the check valve, then remove the banjo from the
check valve using a vice.  Or, you can try and grip the check valve
sufficiently tightly to remove the banjo bolt.  This takes skill,
determination and equipment - I use SC12 ViseGrips, some use specially
ground down 17mm open-ended wrenches and water-pump pliers with the
back jaws ground out..

Beware that the pump to filter to reservoir pipes have only limited
flexibility - the pressed-on pipe that fouls the terminal posts
and is the reason you can't just wind out the check valve is AMAZINGLY
delicate.  If you're going to use any force, wrap some tape around it
to protect it from the terminal posts.

While you're struggling with the check valve banjo bolt on the bench,
just remember you could have been trying this trick upside down under
a car with petrol dripping into your nose, rust dropping into your
eyes, and the pump mounting plate in the way.  This process loses
_all_ of its attraction if you then discover the old hose doesn't fit
the new pump.

At least you can have a cold beer on a bench.

Do not, under any circumstances, grip the new pump in a vice.

--
 Phil Payne
 Phone: 0385 302803   Fax: 01536 723021
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