Disco 2 Replacing fuel pump gotchas

Is there anything I need to watch or look out for when replacing the fuel pump on my 2004 Disco?

Also, I've read up on the carpet removal process, and it seems very laborious, has anyone just cut the carpets at the edges?

You dont have to cut the carpet at the edges, make a proper dimension U shape cut above the pump and lift it like it was the cover of a case then fold it back when the job is done, that's how i did and it's almost invisible.

I did the same. Works well.

Mind and put the rubber ring in the tank first, then slip the pump into the ring

Good idea to note the pipe configuration too. There's 4 of them, all with the same fitting

Cheers

Thanks

Hopefully I'll be replacing my fuel pump this weekend. Before I start, any last words of wisdom?

sierrafery said:

You dont have to cut the carpet at the edges, make a proper dimension U shape cut above the pump

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Just had a thought, but where am I supposed to cut this U shape? Can anyone put up a picture and I'll make a best efforts guess

When I removed my carpet to dry it out it appeared to be factory cut in-line and just hidden by the trim either side of the 6/7th seats. The only cuts that would need to be made would be to continue the factory cut to the back edge either side of the rear door.

In actual fact when my 2004 was in a body shop being repaired the fuel pump died so it was sent to the main dealer in Brighton for diagnosis, someone used the method I've given above to gain access to the pump, I know because the carpet was in factory condition a few months earlier when I had it out while sorting the sunroof leaks.

try to get tank as low on diesel as you can.
and dont cut the carpet do it right its not a big job
clean area well B4 removal, you dont want crap in tank

sierrafery said:

You dont have to cut the carpet at the edges, make a proper dimension U shape cut above the pump and lift it like it was the cover of a case then fold it back when the job is done, that's how i did and it's almost invisible.

Click to expand...

no need to make any cut ,prise out rear plastic strip unscrew the carpet retaining strip and lift carpet at the rear center and pull edges from under trim then fold back

jamesmartin said:

prise out rear plastic strip unscrew the carpet retaining strip and lift carpet at the rear center and pull edges from under trim then fold back

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That sounds a lot easier than having to remove all the side panels, thanks.

jamesmartin said:

no need to make any cut ,prise out rear plastic strip unscrew the carpet retaining strip and lift carpet at the rear center and pull edges from under trim then fold back

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out of curiosity can this method be used o the 7 seater

yes you need to unscrew the covers over the catches as well

ty James

I had quick look at the existing pump this afternoon and noticed that the fuel pipes have got coloured tape around them and thought that they might be colour coded, but all the 'ports' on the pump itself have got green paint dabs on them. So what's the point of the different coloured tape? Are they just to identify which pipe is which?

Oh and I managed to break one of side clips on the power connector!

Hi All

I'm just in the process of replacing my fuel pump, but I can't get one of the fuel lines out of the existing pump. The clip is released, but the pipe itself seems to be stuck in the outlet port. I've given it a good dose of WD40 to try and loosen it, but it won't budge. It feels like there is a vacuum on the port as I can now move the fuel pipe out slightly, but it's getting "sucked" back in to port

Update: I still can't get this pipe out, but it now looks like the pipe is being pushed back in to the port as there doesn't seem to be much slack in it. Its the second pipe (green), so can anyone suggest how I can get some more slack on this pipe? Is it likely to be jammed somewhere?

Any suggestions?

In the process of doing mine but not got that far yet took over an hour to get the inspection cover off with a hammer and chisel as battery drill flat-let you know if I sort your problem

Finally got the pipe off and pump replaced!! I had to slacken off the fuel tank a bit which seemed to allow a bit more movement in the stuck pipe, just enough to get it off the old pump and back on to the new one. Just about to run the purge process on it, and then take it for a quick drive to check for any leak before putting everything back together.

Purge and test run done, all good, no leaks and the engine runs fine.

Wahay mines done too-did not have the trouble with the pipes you had,more of a problem trying to get them out of the way while swapping.Anyway I have a fuel gauge again and a quieter pump-result.
Tell me what did your pump body look like when you removed the old one?Mine was covered in a brown film,but this might be a glycerine deposit from my bio-the intake gauzes were clear and the pump still works just noisey,but if original it has covered 116k so probably best changed anyway.
Be interested to hear what your old pump looked like?

biolandy said:

Wahay mines done too-did not have the trouble with the pipes you had,more of a problem trying to get them out of the way while swapping.Anyway I have a fuel gauge again and a quieter pump-result.
Tell me what did your pump body look like when you removed the old one?Mine was covered in a brown film,but this might be a glycerine deposit from my bio-the intake gauzes were clear and the pump still works just noisey,but if original it has covered 116k so probably best changed anyway.
Be interested to hear what your old pump looked like?

Click to expand...

To be honest, I was beginning to think I'd dropped a bollock and was replacing a new pump with a new pump because there was no discoloration of the plastics in any way on the old one, and in fact it looked almost new!.

My Disco has got 90k on the clock, but I don't know if the pump I replaced today was the original one fitted in 2004. Is there a way to find out?

I'll be interested to see how this new pump affects my mpg as the primary reason for changing it was to try and cure my underfuelling issue, which it appears to have done. I was getting about 30mpg before replacing it.