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changing the in tank fuel pump on a 240 SW

Hello,

I have an '83 240 Gl SW with 180K that is running great. The in tank fuel pump becomes rather noisy if the tank is less than 1/2 full, so I decided to change it.

I encountered couple of problems.

1 The Hayes manual tells you to depressurise the system by removing the fuses for both fuel pumps while the engine is running and let it stall. Regardless of which fuses I take out the main fuel pump keeps on running and the engine never stalls. Is there an easy way to disconnect the pump??

2 I attempted to remove the hoses from the in tank pump, but I had troubles. One just does not come out and it feels like the system is under vacuum. Is there any way that I can completely get rid of the vacuum?? Or do I just have to pull on it harder??

Thanks, Marco.

Reply to
Marco Rolandi
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One hose is attached to the top of the sender unit permanently, the connection is about 50 cm away.

Reply to
Mike F

I just changed both fuel pumps in my 83 wagon recently(like three weeks ago). The toughest part was removing and reinstalling the filler tube. There is a collar on the left side of the back that you reach by angling your arm between the body and the gas tank. It took a 10mm wrench. I took out the tank and was glad I did since it was very easy and five bolts. The two fuel hoses on top of the tank I seperated from the tank inside the car. If the hose was stuck I would have, in a difficult case, try to work soapy water between the hose and metal tube. Disconnect the battery of course. The electrical connection, I disconnected at the connector on the body and let it flop with the tank when I took it out. I don't think it will seperate from the tank access when changing the intank fuel pump. I cleaned up the tank access really well using WD 4o and then tapped it open( it only goes one way) with a solid brass piece of metal. It came off with surprisingly easy taps. The inserted fuel gauge and fuel pump had to be manuerved carefully which is one reason I was glad to remove the tank. Ok, if there was a vaccum I would think that removing the gas cap would solve that problem. You could also remove the hose at the main fuel pump. Mine has a screw clamp holding it on, It seems a daunting task but the only weary part was taking and reinstalling the filler hose collar. Rojo

Reply to
Rojo2G

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