Fuel pump has no power

[Nick1307]

I have no power at the pump, battery fully charged and engine turns over, but still no power at the pump. I have tried changing the relay with no effect I have to confess I am a novice when it comes to 480 electrics - F Reg 480 ES 1.7 - Thank you

[eye of ra]

Which relay have you changed? Please describe its position.

Second an F reg should be 1988 but could be a late registered 1987 so it could have one of two relay layouts. Looking at the top of the pyramid of relays in the relay box under the bonnet is it round or is it square with a plastic connector above it?

[Nick1307]

Thank you for your reply.
Registered May 1989
The relay is in the driverside footwell next to the ECU with a fuse next to it.
The relay box under the bonnet is triangle with rounded corners (From memory)
Regards
Nick

[eye of ra]

I had forgotten that the reg changed in August back then so was much less likely to be a late registered 87 model. (Although I do have a story of a 2002 pre-facelift S60 not being registered till 2007 well post-facelift).

I was asking what the shape of the top relay was inside the relay box not the shape of the box however being registered in 89 and having the relays under the dash answers my question anyway.

Try the following.

Turn ignition to position 2. The relay next to the fuse should click (along with the other relay next to it) after around 2 seconds it should click again (the one next to it should not).

Then turn ignition to position 3. It should click again.

Or if you’re using a multi-meter/voltage tester check there is voltage at the fuse next to the relay as per above (2 seconds at position 2 and permanent at position 3).

[Nick1307]

Thanks for the advice - changed the relay and now getting the clicks with the key posistions and voltage at the fuse, however the pump dosent start. Checked the pump and one terminal had 9v registering, any thoughts?

[eye of ra]

Assuming you are checking the voltage at the connector under the rear seats it has 4 wires they should be as follows.

Brown – Ground
Brown/Blue – Ground
Green/Black – Voltage will vary depending on how much fuel is in the tank.
Green/Red – 12V when ignition is in position 3 (and may require engine to be turning over,mine does but others don’t).

So if you’re getting 9V on Green/Black that is normal.

If the Grounds are ok and you are getting 12V at the fuse and either 9V or nothing at Green/Red you have a wiring issue between fuse and connector.

[Nick1307]

Thank you for your reply, is there any specific areas that the wiring can be damaged? no obvious leakes in the main wiring around footwells?

[jamescarruthers]

How about considering the pump dead rather than considering that there is no power to it. You really need to get a voltmeter accross that green/red wire and ground ‎to see what you are dealing with.

If the pump is dead, be very careful when you extract the pump assembly from the tank not to damage the sender float arm‎. Changing the pump isn't that difficult.

[Nick1307]

Just been out and stuck the meter in the connectors, I get a 12v and can feel a mild jolt in the pump. So maybe it is the pump itself. The car hasnt been started for about 4 years I believe and the pump must have jammed up.

[Alan 480]

Just been out and stuck the meter in the connectors, I get a 12v and can feel a mild jolt in the pump. So maybe it is the pump itself. The car hasnt been started for about 4 years I believe and the pump must have jammed up.

take care when removing the pump, I'd be tempted to slice the rubber pipes rather than pull them off, I managed to pull the connectors off the pump (and given it is a single moulding this was not good ! )

PS don't run the pump near the fuel tank, might be a small flash/flame / bang?

[jamescarruthers]

How about you gve the pump a bit of a jolt and it might get unstuck. I am not saying hit it with a hammer. More like a decent tap with something hard and plastic. Like the back of a large GS screwdriver.‎

You can't hit the pump direct because it is in the tank but a few taps on the top might work. Maybe get someone to put the ignition on and off while you tap?

Mine was stuck when I got it (20 years not started!) but I'm not sure if tapping or relay reseating got it working!

I'd also recommend having a decent amount of fuel in so that it can suck up the fuel up easily if it gets going again. 

[Nick1307]

Thanks for your replies, just got the pump out relatively easily, however it looks a little worse for ware. Not sure if completely knackered, no filter on the bottom, sticky black perished rubber and corroded. Fuel guage contacts also corroded. Taken a couple of photos and could do with seeing what it should look like if anyone can help. Cheers

[jamescarruthers]

If you've got as far as getting it out, you might as well replace it!‎

The filter being missing (which is likely sloshing round in the tank) ‎is likely to have caused it to pick up a few bits that have eventually killed it. A new one comes with a new filter. 

The filters are cheap for all 480's except the very early B18E which runs at a different pressure to all the rest. ‎

Brinkie has posted on here about a rebuild kit. Have a search for that... you could ressurect yours. Haven't done it myself though. ‎

[Nick1307]

I have a new pump kit but not sure how the old pump comes apart, is there a knack?

[jamescarruthers]

I'm sorry I don't know. I just swapped the pump for a new one. At the time I didn't know that a rebuild kit existed! That was a very expensive bit of ignorance as the early car runs a different pressure so it was over £200!

Brinkie told me the kit existed so hopefully he'll be able to tell you. If he doesn't respond on here give him a little nudge on PM.‎

[Alan 480]

I have a new pump kit but not sure how the old pump comes apart, is there a knack?

I can't remember how I fixed mine, not much help then . . .. . ..

I do know I swapped the motor /pump etc from my two litre into the 'cage' from a 1700, as i was unsure of the differences that there might be.
I had broken the pipe when trying to remove it from tank

driving with a broken pipe was shall we say 'interesting', even though just two miles to breakers and back

[jamescarruthers]

Haha, I can sympathise!

Mine was broken by a garage who didn't tell me. When I filled up the tank to full it all sloshed out the top!!!‎

[Nick1307]

Thanks everyone for all your advise, new fuel pump fitted + fuel filter - Petrol flowing - Just got to get it started now
Regards
Nick

[jamescarruthers]

Nice one!