How to swap a 2003 Discovery fuel pump in less than 1 hour
#1
11-09-2018, 04:05 PM
How to swap a 2003 Discovery fuel pump in less than 1 hour
My D II was running rough and the fuel level sensor was acting up. I purchased a new Bosch from Autohaus AZ and set to work on it.
1) Disconnect battery
2) Remove vent cover to rear of right cubby
3) Reach down to bottom and slide thin trim cover towards driver side to gain access to end and lift out to reveal screws .
4) Remove screws from trim holding carpet down, 6 if memory serves correctly.
5) Slide trim left to reveal end on right side and lift out.
6) Remove gent cover behind cubby on drivers side
7) Using a box cutter, reach inside each vent and locate the 1” connection of the carpet, and cut through it (don’t worry, you will never notice).
8) pull carpet on each side from under trim and cubbies, and roll forward to reveal fuel pump access panel.
9) Remove 6 screws holding panel, an lift to reveal fuel pump.
10) Vacuum debris from area around pump
11) Spray WD 40 or Deep Creep around ring securing pump.
12) Disconnect plug and fuel line
13) use rubber mallet and non-ferrous punch to move retaining ring counter-clockwise and remove
14) Lift pump from tank noting the cup will be full of
fuel, don’t spill it, and remove
15) Place new seal ( be sure to read which side is down, it’s marked) into position make sure it is firmly in place.
16) Apply WD40 or Deep Creep around top lip of fuel pump, then slide down into tank as you compress the side springs. Gently press pump through seal until seated.
17) Take ring and place into position and gently tap clockwise until tight
18) plug in and connect fuel line
19) you are now connected, so re-connect battery and test...it may not start first try due to fuel pressure loss. Once checked, shut down
20) Screw cover back into place
21) Pull carpet back into position, utilizing a trim tool, press carpet back under trim and cubbies
22) Place carpet trim in position, slide left so it lays flat, the slide right to match screw holes, and screw down
23) Place screw trim cover in position, slide left, push down, and slide right so both ends are under the cubby trim
24) tidy up your carpet at edges, and you are finished
No need to remove cubbies and trim. Two small 1” cuts to separate carpet from under cubby trim. Best of all, it fits back into place and you will never know you fit it!
Hope this is helpful! Rover on guys and girls!
Note: If you check codes, it may state you had a power fault. Just clear the code...it was the battery disconnect
1) Disconnect battery
2) Remove vent cover to rear of right cubby
3) Reach down to bottom and slide thin trim cover towards driver side to gain access to end and lift out to reveal screws .
4) Remove screws from trim holding carpet down, 6 if memory serves correctly.
5) Slide trim left to reveal end on right side and lift out.
6) Remove gent cover behind cubby on drivers side
7) Using a box cutter, reach inside each vent and locate the 1” connection of the carpet, and cut through it (don’t worry, you will never notice).
8) pull carpet on each side from under trim and cubbies, and roll forward to reveal fuel pump access panel.
9) Remove 6 screws holding panel, an lift to reveal fuel pump.
10) Vacuum debris from area around pump
11) Spray WD 40 or Deep Creep around ring securing pump.
12) Disconnect plug and fuel line
13) use rubber mallet and non-ferrous punch to move retaining ring counter-clockwise and remove
14) Lift pump from tank noting the cup will be full of
fuel, don’t spill it, and remove
15) Place new seal ( be sure to read which side is down, it’s marked) into position make sure it is firmly in place.
16) Apply WD40 or Deep Creep around top lip of fuel pump, then slide down into tank as you compress the side springs. Gently press pump through seal until seated.
17) Take ring and place into position and gently tap clockwise until tight
18) plug in and connect fuel line
19) you are now connected, so re-connect battery and test...it may not start first try due to fuel pressure loss. Once checked, shut down
20) Screw cover back into place
21) Pull carpet back into position, utilizing a trim tool, press carpet back under trim and cubbies
22) Place carpet trim in position, slide left so it lays flat, the slide right to match screw holes, and screw down
23) Place screw trim cover in position, slide left, push down, and slide right so both ends are under the cubby trim
24) tidy up your carpet at edges, and you are finished
No need to remove cubbies and trim. Two small 1” cuts to separate carpet from under cubby trim. Best of all, it fits back into place and you will never know you fit it!
Hope this is helpful! Rover on guys and girls!
Note: If you check codes, it may state you had a power fault. Just clear the code...it was the battery disconnect
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