Fuel injection systems Motronic ML4.1, M2.5, M2.7
The fuel pump is located on the bottom of the car near the fuel tank.
Removal
Warning! Gasoline vapors are toxic! Ensure good ventilation of the workplace.
Warning! Do not allow open flames or sparks near the work area. There is a risk of fire!
Disconnect the ground wire from the battery. Raise the car and place it on supports.
Mark the electrical wires with tape and disconnect them from the pump.
Disconnect the fuel hoses from the pump.
Caution! The fuel system may be under pressure, so cover the disconnected part with a thick rag 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 fuel feed and drain hoses to prevent fuel leakage. If there are no clamps, close the hoses after disconnecting with suitable clean plugs.
Open the clamps and remove the hoses from the pump.
Loosen the bolts and remove the pump.
Installation
Install the pump and tighten its mounting bolts to 4 Nm. Make sure the rubber seal is installed correctly (see arrow in fig.).
Connect the fuel hoses according to the marks and secure them with clamps.
Connect the electrical wires according to the marks.
Remove the clamps from the hoses.
Connect the ground wire to the battery.
Start the engine and check if the pump is supplying fuel and if there are any leaks.
Lower the car.
Fuel injection systems Multec and Motronic M1.5
The fuel pump is located in the fuel tank under the rear seat.
Removal
Warning! Gasoline vapors are toxic! Ensure good ventilation of the workplace.
Warning! Do not allow open flames or sparks near the work area. There is a risk of fire!
Disconnect the ground wire from the battery.
Remove the rear seat.
Pull back the carpet at the entrance.
Remove the plastic cover on the bottom.
Disconnect the wires from the pump.
Caution: The fuel system may be under pressure, so cover the hoses with a thick cloth before disconnecting them.
Loosen the fastening clamps or cut them with side cutters. If there is no suitable clamp available during assembly, use a screw clamp.
Loosen the fuel pump mounting bolts and remove the pump. Collect the dripping fuel in a container.
Installation
Secure the pump by installing new washers and tightening new mounting bolts.
Attention! Replace the cuff with a new one.
Attention! Before screwing in the bolts, cover the threads with a layer of sealant, for example Opel 1503294.
Connect the fuel hoses and wires according to the markings and secure them.
Remove the clamps (if they were installed).
Install the pump into the fuel tank.
Connect the ground wire to the battery.
Start the engine and check that the pump is delivering fuel and that there are no leaks.
Close the mounting hole. Lay down the carpet and install the seat in place.
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