Fuel injection systems Motronic ML4.1, M2.5, M2.7
The fuel pump is located on the bottom of the vehicle near the fuel tank.
Removing
Attention! Gasoline vapors are poisonous! Ensure good ventilation of the workplace.
Attention! Keep open flames or sparks away from the work area. There is a risk of fire!
Disconnect wire "masses" from the battery. Raise the vehicle and place it on stands.
Mark the electrical wires with adhesive tape and disconnect them from the pump.
Disconnect fuel hoses from pump.
Attention! The fuel system may be under pressure, so cover the detachable part with a thick cloth before disconnecting the hoses.
If the fuel hoses are removed completely, they must first be marked with adhesive tape to ensure correct subsequent installation.
Clamp the supply and drain fuel hoses with clamps to prevent fuel leakage. If there are no clamps, close the hoses after disconnection with suitable clean plugs.
Open the clamps and remove the hoses from the pump.
Loosen the screws and remove the pump.
Installation
Install the pump and tighten its fastening bolts to 4 Nm. Make sure that the rubber seal is installed correctly (see arrow in fig.).
Connect the fuel hoses in accordance with the marks and secure them with clamps.
Connect the electrical wires according to the marks.
Remove clamps from hoses.
Connect wire "masses" to the battery.
Start the engine and check that the pump is supplying fuel and that there are no leaks.
Lower the car.
Multec and Motronic M1.5 fuel injection systems
The fuel pump is located in the fuel tank under the rear seat.
Removing
Attention! Gasoline vapors are poisonous! Ensure good ventilation of the workplace.
Attention! Keep open flames or sparks away from the work area. There is a risk of fire!
Disconnect wire "masses" from the battery.
Remove rear seat.
Pull back the carpet at the entrance.
Remove the plastic cover at the bottom.
Disconnect the wires from the pump.
Attention! The fuel system may be pressurized, so cover the hoses with a thick cloth before disconnecting them.
Loosen the fastening clamps or cut them with side cutters. If an appropriate crimp collar is not found during assembly, use a screw collar.
Loosen the fuel pump mounting bolts and remove the pump. Catch dripping fuel in a suitable container.
Installation
Secure the pump with new washers and tighten the new mounting bolts.
Attention! Replace cuff with a new one.
Attention! Coat the threads of the bolts before screwing them in with a layer of sealant, for example Opel 1503294.
Connect the fuel hoses and wires in accordance with the marking and secure them.
Remove clips (if they were installed).
Install the pump in the fuel tank.
Connect wire "masses" to the battery.
Start the engine and check that the pump is supplying fuel and that there are no leaks.
Close the mounting hole. Lay the carpet and replace the seat.
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