ZEST BOLT Service Manual

ENGINE 1.3L QUADRAJET (90PS) 80 ELECTRIC FUEL PUMP The electric fuel pump has a permanent magnet electric motor (1) which controls the pump (2) impeller and a terminal support cover (3) which contains the electrical and hydraulic connections. The pump stage is the single, peripheral flow type with high performance under low voltage and temperature conditions. FUELPUMPOPERATIONCHECKINGPROCEDURE: a. Remove fuel filler cap. b. Release the fuel system pressure. (Refer Fuel pressure relief procedure) c. Turn ignition switch ‘ON’ d. Check fuel pump operation by listening to the sound at fuel pump end. 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 related wiring harness. g. If you do not measure 12V, check for continuity of fuel pump connector as per circuit diagram. h. If there is continuity, replace fuel pump. i. If there is no continuity, repair the ground circuit. FUELPUMPPRESSURECHECKINGPROCEDURE: a. Release the fuel system pressure. (Refer Fuel pressure relief procedure) b. Remove fuel delivery connector. c. Connect fuel pressure gauge (having a range of 0 - 10bar) to the delivery port of the fuel pump. d. Confirm battery voltage (12V) e. Turn ignition switch ON to operate fuel pump and after 2 seconds turn it OFF. Repeat this 3-4 times and measure fuel pump pressure. It should be 4.5 bar. f. If it is not within specification, replace fuel pump. 1. If the pressure is high, check for (i) Fuel delivery line for any blockage. (ii) If the delivery line is clean, replace fuel pump. 2. If the pressure is too low, check for (i) Block delivery line and check if pressure rises. (ii) If pressure does rise, reassemble fuel pump. B. INTANK FUEL PUMP (TANK UNIT): The electric fuel pump is assembled in a single unit with the level gauge. 1. Fuel supply connector 2. Fuel return connector 3. Electrical connection 4. Electric fuel pump 5. Fuel level sensor 3 1 2 4 5