New Fuel pump
 

Just said I'd share my week so far....
Driving home Monday night on a back road about 9pm, suddenly loose power and come to a halt. Turns over and won't restart. I have a fair idea it's fuel
Related as there was no misfire just died. Check the fuse to find the fuel pump 15amp is blown. Quick swap and after a couple of seconds that blows too.
Ring my buddy and we tow it to his work, local motorfactors, and I go home.

I pull the pump out Tuesday on my lunch break and we order a replacement for today, (the good one, was a cheapy that was in it) and it landed today

Take a early lunch to fit the new one. Becomes a extended lunch as it's a pig to
get it in the tank, swearing and nearly tears. However after eventually getting it in, and yes I had both panels open for all the difference that made! It starts and runs fine!
I now am back at work, 3hrs later, with the latest sent from texaco splashed all over!
Still at least I can give herself her Astra back....

There is definitely a technique to getting the pumps back in.... with practise its a sub 10 minute job, first time though, 3 hours aint bad at all +++

Glad its up and running again, fuel pump used to be the number one cause of breakdown on the D2, more so than gearbox failure.... +++

Ok a update. Got home eventually, over 2/3rds of fuel in it but it just died till I gave it another gallon?!?!would it not be seated right?

Yes, the pick up failing even with loads of fuel in the tank is often a symptom of the fuel pump not being sat properly and so not sealing fully.....

I feel some more eau de Texaco coming your way..... :rolleyes:

Or just keep it full, which is what folks have been known to do ! +++

Ok thanks! Sure at least it's at home now so can do it under less pressure! I'll pull apart and start again.... Woohoo!!!

Had the same problem with my car when I bought it due a change of pump. Tried refitting it a few times myself (even bought an endoscope/borescope so that I could see what was going on down there) but I got sick of crouching in the boot whiffing petrol fumes so I decided to let someone else do it. 3 different garages tried and failed, so I continued to drive the car for 3 years, always filling up whenever it got down to half a tank. Eventually I replaced the entire tank. I suspect in my case something may have been damaged/cracked in the tank, preventing the pump assembly from achieving a perfect seal. Hopefully you'll get yours seated correctly on the next attempt +++

Thanks for the reminder, fuel pump is on my list as a preventative maintenance, but I keep forgetting about it. After 15 years on original pump I think its due.

Fingers crossed I'll get it in properly over the weekend. Was kinda under pressure doing it in the car park/outside mates work/lunch break and so forth!

Yes, definitely a trick to it.
Two things are a significant help:
- Make sure the receiving assembly in the tank is hanging off its hook over the filler tube - you'll never get them mated properly if it's not on the hook.
- There's a corkscrew action which makes the pump assembly a piece of **** to remove (anticlockwise) and reenter (clockwise) the tank. Pay attention to its orientation when you pull it out and start your reentry at the same orientation - there shouldn't be any resistance to getting it in or out, if you fight it you're doing it wrong.


Check the hoses on the assembly. I had a split in one of mine which stopped the system pressurising properly and stopped the car from starting.

Whatever you do, do not overtighten the long bolt. There will be minor resistance while it squashes the rubber on the metal rubber gasket. Once it bottoms out (goes solid) stop tightening. The captive nut is in a thin housing. Distort that and you'll never get it undone ever again...

Thanks for the tips! Makes a lot of sense. The hanging of the the filler tube though, what am I looking for there?