Fuel Pump replacement on a 94 D90 - Defender Source
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  #1  
Old February 5th, 2014, 09:08 PM
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Fuel Pump replacement on a 94 D90

I have to replace the fuel pump on my 94 D90 tomorrow. Never replaced a D90 fuel pump. Any info is greatly appreciated.
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  #2  
Old February 5th, 2014, 09:20 PM
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Quote:
Originally Posted by 101stAirborne View Post
I have to replace the fuel pump on my 94 D90 tomorrow. Never replaced a D90 fuel pump. Any info is greatly appreciated.
Did you check the fuel pump relay ?
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  #3  
Old February 5th, 2014, 09:29 PM
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Originally Posted by rd10014 View Post
Did you check the fuel pump relay ?
x2. It would be a shame to replace the fuel pump for that not to be the actual issue. How have you confirmed?
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Old February 5th, 2014, 09:36 PM
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Start soaking those skid plate bolts and the fuel line fittings (where the steel lines end and turn to rubber on top of the tank) with some pb blaster now. Best if the tank is nearly empty as well.

Unhook the filler tube from the tank. Cut and Bend a 6in or so metal coat hanger into a U so you can undo the special fitting for the Evap system. Push the U into the little holes on the fitting and you should be able to pull them apart. You might need to push and pull a bit to get them free. Mine seemed like it took a good amount of force to undo.

Use a jack to help lower down the tank. You can get it down about half way so you can get the wiring harness clip off.

When the tank is down mark the position of the retaining ring on the tank and ring for a "seated position". You can take the rubber lines off now, if you have time, take them to a shop and make some new ones. Or buy some new ones since you were there. Get a new sealing gasket too, they are pretty cheap from multiple sources. A little grease to help the gasket seat helps.

I used a rubber strap wrench to help get it off and on.

Really pretty easy if your tank is low on the fuel, otherwise I would try and siphon some out.

AND if you don't have one....alloy skid plate time?
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  #5  
Old February 5th, 2014, 09:52 PM
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How much is a new fuel pump? What are early signs of failure? Mine is fine but figure it will need replacing at some point.
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  #6  
Old February 5th, 2014, 09:57 PM
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Quote:
Originally Posted by rd10014 View Post
Did you check the fuel pump relay ?
your welcome!
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  #7  
Old February 5th, 2014, 10:52 PM
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Quote:
Originally Posted by WeBeCinYa View Post
How much is a new fuel pump? What are early signs of failure? Mine is fine but figure it will need replacing at some point.
Low fuel pressure, inconsistent misfire, truck won't run at all, fuel cant keep up when flooring it.
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  #8  
Old February 6th, 2014, 12:50 AM
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I'm confident you checked the $3. Inline filter first. Pump change Isn't fun, will take a large portion of your Saturday, but should cure you of any bad smoking habits.
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  #9  
Old February 6th, 2014, 01:49 AM
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Having dropped and reinstall the fuel tank a few times take your time. Shop jack is recommended.
Also good time to consider adding any crossmember bolt on like a pintle or drop hitch
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  #10  
Old February 6th, 2014, 05:58 AM
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I've had my pump assembly out, but never looked at the guts. Will the AC Delco EP241 work if all that's needed is the pump? that's what I used in my '95 Discovery. Paid about $60 for it I think.
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  #11  
Old February 6th, 2014, 06:23 AM
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Good time to restore and/or preserve the rear frame sections, fuel cradles, and rear crossmember. I'd pressure wash everything with Simple Green, meticulously clean/degrease the area, and paint with the Eastwood line of products. Their green internal frame paint is good stuff. You could use an entire can fogging the inside of the rear cross. All of the cavities are reachable.
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  #12  
Old February 6th, 2014, 08:56 AM
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Maybe inspect the other components along the fuel system. It is possible other components that are not functioning at par caused the fuel sender to fail.

Clay
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