DIY gas pump repair

In detail: do-it-yourself gas pump repair from a real master for the site my.housecope.com.

We loosen the tightening of the clamp and remove the supply hose from the fitting.

Use the “14” wrench to unscrew the union and disconnect the fuel pump outlet pipe.

Unscrew the two bolts with the “12” head with an extension.

... and remove the fuel pump.

A gasket is installed between the pump and the cylinder block.

We unscrew 8 screws around the perimeter of the pump and, remembering the position.

Pressing on the center of the diaphragm, turn it through an angle of 90 ° and remove the diaphragm together with the stem and spring.

... and remove the plastic partition with valves and a sealing gasket.

Carefully sink the valve leg with a screwdriver.

... remove the valve from the back of the partition.

Using the “17” wrench, unscrew the fitting and remove the mesh filter from it.

We assemble the fuel pump in the reverse order.

We orient the pump cover according to the arrow indicating the direction of fuel movement.

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Is it worth undertaking an independent repair of an electric fuel pump?
1. Why does the electric petrol pump fail?
2. Technology for repairing an electric fuel pump.
3. What you need to repair an electric petrol pump.

All fuel injection systems, which in most cases are installed on modern automobile internal combustion engines, will be equipped with a fuel pump device driven by an electric DC motor. The electric fuel pump device can be located directly outside the fuel tank, but next to it under the bottom of the body, or in the fuel tank itself, where, in this case, it will be immersed in gasoline.

The electric fuel pump device is designed to pump fuel directly into the injector from the gas tank. Such a device will provide fuel to the injectors under the influence of a certain pressure. All electric fuel pumps are installed on vehicles that are equipped with electronic fuel injection into the system.

Video (click to play).

In its modern form, there are two types of electric fuel pump: suspended and submerged. The main difference between the two devices will only be the presence of a fuel filter on the tip of the device, which will have a different possible shape. The part is quite reliable, although breakdowns will not be very rare.

So, The main reasons for failure for modern injection systems of a gasoline pump device are as follows: idling or emptying the vehicle's fuel tank. However, many car manufacturers have already stripped their creations of these shortcomings. Now, in the event that the fuel runs out, smart car electronics will spontaneously stop the operation and activation of the electric petrol pump, which will save it for many years of life.

Often, before its "death", the electric fuel pump device makes a lot of noise. It is important that the motorist does not miss this noise and makes the necessary replacement in time. This must be done in order not to resort to using a tug in the future.

The basis of the electric petrol pump device is an electric motor. If the entire resource was focused only on him, the fuel pump would be enough for as much as 200,000 km.Nevertheless, the whole point is that the fuel pump device uses the fuel itself as a lubricant, which for this reason has a somewhat terrifying characteristic: it has many tiny particles that, in the course of time and the operation of the car, will grind off all the working elements of the pump. and he will begin to lose its working properties long before the electric motor device fails; in the event that the fuel filter device was very dirty, the situation will be aggravated by an order of magnitude more.

It is important to note that in most cases, the efficiency of the fuel pump device will be much higher than necessary, since the initial signs of severe wear can be determined in time in accordance with extraneous noise arising from nowhere. This will be possible only in our conditions, since already worn out mechanical pumping parts will begin to emit a sound.

Even in spite of the fact that the performance of such a pump is much higher than its operating parameters, one should not delay its repair. The thing is that when the internal combustion engine is started directly, the voltage of the on-board network will drop sharply, as a result of which the pump performance will decrease; it may be sufficient to run the engine, but may not be sufficient to start itself. As a result, you can get the electric petrol pump jammed, as a result of which the vehicle will finally become.

Of course, the wear rate can be reduced by modern cleaning of the fuel system, regular replacement of the fuel filter. However, in winter periods, adversity can also arise, since if water is present in the fuel, it can freeze, which will short-circuit the armature winding. It can also cause the fuel pump to jam. The very wear of the fuel pump will be accompanied by a very interesting symptom: fuel consumption will decrease. Nevertheless, with this, the engine throttle response will decrease, and therefore there is nothing to rejoice here.

Initially, it is necessary to completely relieve the existing pressure in the fuel system. This is quite simple to do, since you just need to remove the fuel pump relay, start the internal combustion engine and wait until it stalls. Next, you need to remove the terminals from the battery itself, and remove the fuel module itself from the gas tank. A number of cases provide for a partial analysis of the cabin, since the hatch itself can be located directly under the sofa. The removed pump must be defectoscopied, and after this procedure, all the necessary repairs must be carried out.

It is very common for the fuel pump to jam due to the fact that the protective coating that protects the inner surface of the bronze ring is simply erased. As a result, you can get the destruction of the ring itself, as a result of which it wedges. The problem in general will not be in the low quality of the spraying itself. The point is in the fuel, which was susceptible to the action of different chemical elements, and the problem can be solved only by changing the fuel. If this kind of breakdown occurs, then a new ring must be made, and its top layer must be cemented.

In addition, it is necessary to replace the rollers, as they will also be triggered., and if only one ring is replaced, the operation of the fuel system and pump will be ineffective. Among other things, the electric motor of the electric fuel pump may also fail. In this case, the collector will fail or the brushes will wear out. If there is an opportunity to call at the service station, then it is better to rewind the anchor. If axles are produced, then they must be replaced with new ones with passport parameters. All broken and worn parts of the fuel module also need to be replaced with new ones.As a result, the fuel module will be assembled and installed back into the vehicle.

To be honest, the process of repairing the fuel pump will serve as an excellent reason for thorough cleaning of the car's fuel system, filters and gas tank, replacing all other consumable items.

If you look at it, the electric fuel pump device cannot be repaired: so it was conceived by the manufacturers, if faults and malfunctions are identified, they will require total replacement. Nevertheless, the masters of automotive practice have shown that with a bright mind and caution when opening the aluminum case, all further procedures will be quite easy, and the gas pump device can be safely repaired, but using special expensive equipment.

From all of the above, the motorist can conclude that it is not enough to have only one desire and skill to carry out the necessary work. You need to have special equipment, which is quite expensive and does not always pay off. That is why motorists recommend, due to economy and budget, to use high-quality car services and workshops, since everything can be done there quickly and efficiently. In addition, it will also be much cheaper than purchasing the necessary equipment. Thus, the practice of automotive repair of an electronic fuel pump shows that such devices can still work for a very long period of time.

It turned out a bit long, but maybe my story will help someone solve a similar problem without stepping on the rake that I stepped on.

For the last year, signs of a dying gas pump began to appear in the car (several times when the ignition was turned on, the gas pump did not turn on).
Since I had not yet climbed into the fuel system (it was somehow scary to get involved with gasoline), for several months I did without any intervention at all - after a few minutes of waiting, the pump still began to work. In January, while visiting, I left the car in the parking lot and it did not start again. After that, I climbed to rummage through the forum. Armed with information on what to do, they took the car with the father-in-law to him by a car service on a tow truck. We checked all the places - the relay, the fuse, the voltage on the pump itself. The electrician immediately tried to put the block on the main relay - no results. The removed pump miraculously worked, put it back and changed the relay to a new one (the electrician said that most likely the relay was stuck). Somehow I didn't really like his conclusion - after all, at the very beginning he connected the block to a known working relay. But I did not argue - they are engaged in cars every day, they probably know better. Now I understand why - the main thing for them is to make the car start up faster, and not to scrupulously search for the cause of the malfunction (and this is already so in the blood that they even do the same to relatives).

The rest of the winter and the whole spring I left without any problems, and in May the same garbage started again once a week. Tapping the pump with a hammer helped. Thought about a new fuel pump. I didn't want to put on a domestic one, but a toad strangled to spend two thousand on a Boshevsky one. When the sound of the pump became floating (as if someone was changing the speed), I strangled the toad and decided to buy a new one. And then the father-in-law remembered that he had a spare on the balcony, never used.

They decided to change at the dacha. As it turned out, there is nothing difficult in replacing it. Since the car did not start for a day before the replacement, it was not even necessary to relieve the pressure in the fuel line after the pump. Only a glass leaked from the gas outlet. The inlet pipe was plugged with a conventional plug. Actually, this is the dumbest place when replacing. Each time the fuel pump was removed / installed, a portion of gas flowed into my sleeve on the inlet pipe.When removing the old fuel pump, the father-in-law found that the inlet pipe in the middle was cracked a little (because of this, it was periodically etched into the cabin with gasoline through the hole for the wires to the pump under the rear seat). The pipe was replaced. They put in a new pump. We turn on the ignition - silence. The spare pump behaved the same as the old one and did not turn on even when 12 volts were directly connected to it.

Nothing to do. Without touching the new pump, I decided to disassemble the old one and try to clean it, since I found a description of how to do this on the forum before replacing it. There was no description with me, and I didn’t remember it. The only thing left in my memory was that it was a real operation for me. Perhaps, domestic gas pumps may differ structurally (after all, three different manufacturers do it), but both the old and the new ones were of almost the same design.

1. Remove the retaining ring from the inlet end. I did not have special pliers, but they were perfectly replaced by platypuses with the ends of the jaws bent to the side.

2. Rotating along the axis back and forth, pull out the plastic pump cover.

3. Taking platypuses by the central cylindrical ledge (in the photo they are straight, but disassembled by others with bent ends - they are much more convenient) and resting their ends against the protrusions on the inner edges, also swinging along the axis and pulling outward, remove the pump itself - the most difficult thing has been done.

Read also: DIY Lancer 9 engine repair

It is worth noting that both types of fuel pumps are installed on some cars. The function of one is to work with small volumes and high pressure, the domain of the second is to work with large volumes and low pressure. Image - DIY gas pump repair

The first alarm, characterizing the disruption of the fuel pump, is the intermittent movement of the vehicle. The appearance of this sign means that do-it-yourself repairs are required.

Prolonged running of the engine also indicates certain malfunctions in the gas pump. In one "fine" moment, the engine may not start at all.The root cause of this is the pressure drop in the system, therefore, first of all, they are checked for leaks.

You can check the fuel pump device with a special indicator, which can be purchased at an auto parts store. The installation of this device is done by hand according to the attached instructions. When the engine is turned off, the pressure in the fuel network is diagnosed. A decrease in the pressure level in 5-7 minutes to 1.6 atmospheres indicates a malfunction in the fuel regulator or injector. Identifying the "culprit" is a stage preceding the repair itself.

To diagnose the operation of the fuel pump and check the pressure readings, you can use a pressure gauge. The device must be connected to the fuel rail and brought out to the windshield using the edge of the car hood. Turning on the ignition is a start for fixing the readings with a pressure gauge. The rate of pressure fluctuations is from 300 to 380 kPa. After that, the car must be accelerated to 3rd gear and the readings of the device must be checked again. If the pressure level has not changed, then there is no cause for concern, and some other component of the machine needs repair.

If the pressure level in the fuel system changes, consult a professional.

If the car starts to stall on the move, the reason most often lies in the electrics. You can confirm or deny these concerns by testing the fuel pump relay. Diagnostics can be done by hand by connecting a control light to the gas pump. When the ignition is turned on, this lamp should light up for 2-3 seconds. In the absence of this signal, repair of the car's electrical system is required.

Fuel leakage can be eliminated simply by replacing gaskets, valves, diaphragms and filters. You just need to know the structure of the fuel circuit, the replacement itself does not cause difficulties even for amateurs. It is better to entrust the repair of electricians to the specialists of a car dealership or a large service center.

Older car models have carburetors and a mechanical fuel system. Such a device breaks less often compared to injection-type cars. In the latter, an electrical system and a modern gas pump are installed. An electronic system monitors the level and rate of fuel delivery. The functions of the fuel pump are to transport fuel from the tank to the place where the mixture is formed, as well as to create the required pressure level.

It is easier to carry out any repairs with your own hands if the sequence of individual operations is known. First, you need to check the device for the absence of factory debris (small metal particles) inside the fuel tank, which can enter the pump and disable the latter.

All repair work related to the functioning of gas pumps can be divided into several areas:

1) if foreign particles are found in the fuel tank, it must be flushed. If it is impossible to wash all the debris, the tank must be replaced;

2) oil leakage is a signal to check the junction of the cylinder block and the fuel pump. Insulation gaskets are also checked;

3) to remove the pump, it is required to disconnect the supply and supply gas lines, then unscrew the fastening nuts and remove the washers on the springs. After that, it is possible to dismantle the fuel pump itself;

4) a malfunction in the pump can cause a deformed diaphragm. In this case, it must be reinforced with plastic wrap;

5) cars with high mileage may have diaphragm springs weakened from the load. Repair - stretching the spring back into place.

This article answers the car owner's question: is it possible to independently repair the fuel pump in an injection-type car? It can not only be done by hand, but it does not represent anything complicated, which is confirmed by the video:

Regardless of the type of fuel for which the car is designed, it must be supplied to the engine without interruption.Its reliability and stable operation directly depends on this. The quality of domestic gasoline traditionally leaves much to be desired - most of the mechanisms and engine systems suffer from this, primarily the gasoline pump. To prevent its breakdown at the most unexpected moment, you need to know the signs and causes of the malfunction, as well as adhere to preventive measures to maximize the life of the gas pump.

The fuel pump is designed to transfer fuel from one point to another. In a car, the role of the first point is played by the fuel tank - the tank, and the second - by the engine, where the pumping takes place. This process takes place at a certain pressure, which is maintained by the pump reducer, which is a very important point.

According to the drive type, fuel pumps are divided into 2 types: electrical and mechanical. Inside the first one there is an electric motor with a mini-pump, which operates from the mains and continuously pumps fuel into the engine. The second type is found less and less, as it is installed on carburetor machines, and functions due to the reciprocating movement of the lever.

Mechanical fuel pumps

In a mechanical gasoline pump, malfunctions most often occur due to wear of the gaskets and the formation of leaks between parts of the body. As a result, the tightness of the structure is broken, air gets inside, fuel stops getting into the carburetor and the engine stalls. A similar consequence is diaphragm rupture and valve breakage. At the same time, the car starts to move in jerks until the fuel supply stops at all.

Electric fuel pumps

On machines with mechanical and electronic injection, the signs of a fuel pump malfunction are slightly different, but they can be classified into certain groups:

The engine will not start. Rotation of the starter with dry spark plugs does not cause flash in the cylinders. There is no pressure in the fuel line, or it is extremely low, the pump whirring when the ignition is turned on or the starter is running is not audible.
The engine does not start, although there are occasional flashes in the cylinders. There is pressure in the fuel line, but without a pressure gauge, its value cannot be determined. Dry candles.
The engine starts, runs normally at idle speed, but pressing the accelerator causes it to stop. If desired, it is possible to raise the revs to medium, but attempts to move away lead to the fact that the engine stalls. There is a black coating on the candles, the operation of the gas pump is characterized by a changing sound.
The engine starts, keeps idling speed normally, and picks them up easily at neutral speed. When driving at medium and high speeds, "twitching" is observed. It happens that after a certain mark on the tachometer, the speed does not pick up, and the engine stops delivering the required power under load. In this case, the candles are white, and by their appearance it seems that the ignition is too early on the car or a lean mixture is supplied.

It is worth noting that the above symptoms of fuel pump malfunctions are typical for other engine breakdowns, and they cannot be used to unambiguously diagnose a fuel pump malfunction. For example, rpm also floats when there is a problem with the air sensor, throttle valve, clogged injectors, or low-quality fuel.

Disassembled mechanical fuel pump

A mechanical fuel pump can fail for the following reasons:

In case of violation of the integrity of the diaphragm.
After accumulation of dirt under the valves.
If the filter is clogged.
When the spring loses its elasticity.
In case of violation of the tightness of the case.
With natural wear of parts during operation.

The electric fuel pump of a modern car is quite reliable. Malfunctions in it arise only due to the influence of certain factors, among which the following are most common:

Burnt contacts inside the fuel pump

one.Defective wiring in the form of dirty, rusty, melted or damaged wires in the fuel complex interferes with the operation of the device and also limits the required current parameters, making it difficult to pump fuel.

2. Debris and impurities in the fuel tank in the form of rust, dirt, water, mechanical particles that penetrate into the fuel pump and cause its breakdown.

Clogged fuel pump filter

3. A clogged fuel filter with debris from the tank contributes to a sharp decrease in the pressure created by the pump and deterioration of its operating parameters.

Molten fuel pump turbine

4. Prolonged driving on a car with a small amount of fuel, in which the pump is not submerged, experiences significant overheating, quickly consumes internal lubricant and fails.

5. Natural wear of the rubbing parts of the pump.

Checking a mechanical fuel pump

The operation of the mechanical fuel pump is checked by disconnecting the hose from the manual pumping outlet, after which the fuel is pumped with a lever on the pump, which, in the absence of breakdowns, should be supplied with a jet in time with the movement. During the procedure, a rag is placed under the nozzle so that gasoline does not spill in the engine compartment.

Checking malfunctions of the electric fuel pump is carried out in the following ways:

Checking the filter on an electric fuel pump

1. Checking the filter. Most often, problems with the operation of the device arise when the coarse filter is clogged, which is characterized by the appearance of the following symptoms:

Drop in motor power;
Weak traction at high revs;
Difficulty starting the engine;
Unstable operation at idle and low speed.

Checking the pressure in the fuel rail

2. Checking the pressure in the fuel line, the results of which can more accurately determine the problem with the pump:

At idle, the pressure should be 0.23-0.25 kPa;
When starting the engine, the pressure should reach 0.3 kPa;
In the transient mode - 0.28-0.3 kPa.

If in the transient mode the pump does not deliver the required pressure, then there is a high probability of clogging of the coarse filter mesh. If the pressure in the fuel line with a pinched return pipe does not reach 0.4 kPa, this means that the degree of pump wear is quite high.

3. Checking the pump for mechanical damage. If the pump mechanism is significantly worn out or dirt gets into it, a characteristic noise will be heard. When the ignition is turned on, the fuel pump works, but with obvious signs of a malfunction of the mechanism.

Repair of a mechanical fuel pump

Repair of a mechanical fuel pump consists of installing a new repair kit (diaphragm and valves) on it, and, if necessary, a worn out pusher with a spring. A deeper repair of this device is impractical, since the cost of purchasing and repairing worn parts is close to the cost of a new product. If the pump housing is deformed or damaged, a complete replacement is required.

Electric fuel pump repair

The electric fuel pump is equipped with a non-separable body, and if it breaks down, the product is replaced with a new one. Opening and repairing it is impossible without special skills, equipment and spare parts. But some workshops take on similar work, the price of which is lower than buying a new pump. The main breakdowns of the device are as follows:

Broken brushes and engine manifold. The repair provides for their replacement with new ones.
Breakage of the plastic coupling connecting the rotor and the armature shaft of the engine. The clutch is replaced with a new one.
Anchor breakage. The repair involves the rewinding of this part.

The described actions allow you to eliminate the malfunction of the fuel pump on all VAZ models: 2101, 2102, 2103, 2104, 2105, 2106, 2107, 2108, 2109, 21099, 2110, 2111, 2112, 2113, 2114, Niva, Priora, Kalina, Grant, Vesta and most foreign cars.

Video (click to play).

The best prevention for the long-term operation of a gasoline pump is its careful and correct operation, as well as compliance with the following rules:

All scheduled car repairs must be accompanied by the replacement of all fuel filters.
It is necessary to control and ensure the cleanliness of the fuel tank and filters, as well as monitor the quality of the refueled fuel (absence of water, sand and other impurities in it).
Eliminate the possibility of water getting into the fuel tank.
Protect the body of the gasoline pump from mechanical stress, which causes dents and cracks that contribute to the development of corrosion processes.

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