SAFARI

4 PL FUEL SYSTEM

ELECTRIC INTANK FUEL PUMP WITH IN BUILT

PRESSURE REGULATOR :

The electric fuel pump is located inside the fuel tank. It is

a positive displacement pump assembly driven

by motor to provide continuous flow of fuel to the high

pressure fuel system from fuel tank.This pump is

inbuilt with pressure regulator. The pressure regulator

maintains the pressure in fuel line. A return line is

provided after fuel filter so that incase if pressure tends to

rise, excess fuel returns back to fuel tank.This

ensures the constant operating pressure of 3.5 bar in the

fuel rail.The fuel pump consists of check valve tomaintain

pressure in the fuel feed line evenwhen the fuel pump is

switched OFF. Fig. 12.

Removal / Inspection :

Before removal, check fuel pump for operation as

follows :

a) Remove fuel filler cap.

b) Release the fuel system pressure as mentioned

above for‘removal of tank’.

c) Turn ignition switch‘ON’

d) Checkwhether fuel pump is runningby listening

for sound at fuel filter inlet.

e) If no sound is heard, measure voltage between

fuel pump electrical connector wire to chassis

ground.The voltage should be approx.12V.

f ) If voltage is not correct, check for fuel pump relay

and relatedwiring harness.

g) If you do not measure 12V, check for continuity

between fuel pump connector terminal wires

(battery) and (ground).

h) If there is continuity, replace fuel pump.

i) If there is no continuity,repair ground circuit.

j) For fuel pump removal fold the carpet between

jump seat floor and open the plastic lid located

under the floor carpet. Disconnect electrical

connectors. Release the fuel system pressure as

already explained in fuel tank removal.

Disconnect the quick fix couplings by pressing

the twotabs. Loosen fuel pumpmountingscrews.

Push the ring asidewhile taking pump out.

k) Check fuel pump filter for evidence of dirt and

contamination. If so, cleanandcheck for presence

of dirt in fuel tank.

Check fuel pump for pressure :

a) Release the fuel system pressure as mentioned

above for ‘removal of tank’.

b) Disconnect negative battery terminal.

c) Remove fuel delivery line connected to

underbodybundy tube.

d) Connect fuel pressure gauge(having a range of 0

- 10bar) to the delivery line.

e) Check that battery voltage is @ 12V

f ) Turn ignition switch ON to operate fuel pump

and after 2 seconds turn it OFF. Repeat this 3-4

times andmeasure fuel pumppressure. It should

be 3.5 bar.

g) If it is notwithin specification, replace fuel pump.

If the pressure is high, check for

a) restricted fuel return line

b) If the return line is clean, replace fuel pump.

If the pressure is too low :-

a) Block return line and check if pressure rises.

b) If pressure does rise, reassemble fuel pump.

c) If pressure does not rise, replace fuel pump or

check for leakages..

After checking fuel pressure, remove fuel pressure

gauge.

Connect fuel delivery pipe back to original position

andensure thatquick fixcouplingsareproperly fitted.

With engine OFF and ignition ON check for fuel

leakage.

Warning :

Unless replacement is necessary, fuel pump, fuel level

gauge should not be removed from the tank since the

rubber parts i.e. gasket, seals etc.may get exposed to air,

light andmay become hard.

Never apply an excessive force to the fuel pumpnipple or

leadwire.This may result in bent or poor contact.

Assembly :

Assemble the pump in reverse order of removal as

explained in 1.j. (above)

Fig. 12