Roadster Fuel Pump Change
How to remove and replace the Roadster fuel pump
It goes without saying but I'll say it anyway because there are a lot of nob heads out there.
Petrol is flammable and when it's in a confined space, the petroleum gas can be explosive.
Make sure you are in a well ventilated area, ideally with as little fuel in the tank as possible.
Don't use a naked flame and be careful about anything that can create a spark.
Locating The Fuel Pump
Open the boot and lift the carpet up behind the soft top flap.
Over to the left you will find a big rubber cover with the smart logo on it.
Grab one of the tabs and pull it away from the car.
This reveals the fuel pump in all of its boring glory.
One TRn member reported that a mouse had chewed one of the pipes which had
caused a leak.Look for obvious holes in the pipes and signs of fluid leaks around the
pipe connections and the main circular retaining nut around the outside of the pump.
Disconnect the electrical connector by lifting the black tab and pulling the connector towards you.
Both the out and return lines have blue clips built in. Push the pipe in, press the blue tab and then pull the pipe. Pushing the pipe in 1st takes the strain out of the blue clip making it easier to push.
Undo the large retaining nut that runs all the way around the pump housing. It will
undo in the same anti-clockwise (counter-clockwise) direction as a standard nut.
I can tell you now through experience, it will not be easy to undo.
Once you have removed that, the pump lifts out. Tilting the pump allows it to exit
the hole in the bodywork and fitting the replacement is the opposite of removal.
Clean all mating faces and check the seal of the new pump is ok before fitting.
Hand tighten the pump nut to ensure it isn't cross threaded before tightening.
Reconnect the electrical connector and the 2 pipes securely before starting the car.