changing the in tank fuel pump on a 240 SW

[Marco Rolandi]

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.

 

[Mike F]

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.

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

--
Mike F.
Thornhill (near Toronto), Ont.

NOTE: new address!!
Replace tt with t (twice!) and remove parentheses to email me directly.
(But I check the newsgroup more often than this email address.)

 

[Rojo2G]

I decided to change it.
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