How do I replace Astra F fuel pump

[John]

Hi,

Looks like the fuel pump in my 1992 Astra F (1.4 petrol) has died.
Relay clicks as normal to prime the system on twisting the ignition
(without cranking), but I can no longer hear the pump. I disconnected
the power lead to the pump, folded back the leads on a small 12V 15W
parking bulb and stuck this into the power lead connector. On twisting
the ignition, the bulb would light for around 2 seconds as hoped, so
relay and fuse must be ok.

I gently tapped the pump to no avail, so I'm tempted to replace it
myself. Has anyone done this on an Astra (or similar) before, and if
so have you any pointers please? It looks like all the bolts are
accessible by removing a round plastic cover under the rear seat and
there only seems to be one pipe to disconnect. Are new gaskets
required? Are there other internal plumbing or electrical connections
to watch out for (e.g. does the pump unit contain electrics for fuel
gauge, etc)?

Thanks in advance,
John.

 

[me140]

They aren't bad to do but as you are working on a fuel based component
safety is very important.
Yes you need a new gasket - don't strip the threads when you refit it.
The pump wires are usually soldered on so you need a soldering iron and do
this well away from the car and make sure you have cleaned all the petrol
off the pump assembly.
There is a filter on the bottom of the pump and these are a tw*t to get off
so you might want to get a new one before you strip in case it breaks on
removal.
Just check the wires haven't rotted off the top before you strip it.

 

[John]

They aren't bad to do but as you are working on a fuel based component
safety is very important.
Yes you need a new gasket - don't strip the threads when you refit it.
The pump wires are usually soldered on so you need a soldering iron and do
this well away from the car and make sure you have cleaned all the petrol
off the pump assembly.
There is a filter on the bottom of the pump and these are a tw*t to get off
so you might want to get a new one before you strip in case it breaks on
removal.
Just check the wires haven't rotted off the top before you strip it.

Hi,
Thanks for the answer. Is the fuel gauge sender part of the unit and
if so, how is it wired? I can only see one connection and this is for
the pump.
John.

 

[me140]

The wires for the pump will be red/blue and brown. I can't remember the
sender colours but they are a lot thinner.
The sender isn't part of the pump unit. If you only have 2 wires going to
the unit under the seat then your sender is a separate unit and will enter
the tank at another point underneath the car.

 

[John]

The wires for the pump will be red/blue and brown. I can't remember the
sender colours but they are a lot thinner.
The sender isn't part of the pump unit. If you only have 2 wires going to
the unit under the seat then your sender is a separate unit and will enter
the tank at another point underneath the car.

The connector I see has only a red/blue wire and a brown wire as you
indicated. The fewer things I have to interfere with the better, so it
looks like I might not have to touch the fuel sender mechanism, which
is great. I've got a new pump and filter, so I'll get working whenever
the rain stops. Thanks again.
John.