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Fuel pump assembly replacement (Punto 1,1 SPI)
Guide, how to replace bad fuel pump (entire assembly).
Published by pmx007pl
30-12-2012
Difficulty Level: 1

User Rated:Unrated

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Smile Fuel pump assembly replacement (Punto 1,1 SPI)

When your car is hesitating (engine almost die) while you want to accelerate and under the hood (bonnet) everything is fine (like ignition system, timing belt, lambda sensor, TDC crank sensor, you have fresh oil, etc.), it's time to look closer on fuel system (replace external fuel filter, and if it's still no good, fuel pump may be guilty - you can measure the pressure and/or inspect the pump and tank, to check what's inside, pump inlet clogged or something like that).

In my case it was easy, because fuel pump one day started to squeak/whine.

There are fuel pumps as a separate device or "complete assembly" kits available.
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I decided to buy whole assembly kit.
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Punto 1,1 SPI (it's 1 bar pressure pump, for more powerful engines pumps are 3 bar).
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In this type of kit, you must install level indicator, floater, correct way.
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Important thing. With new pump, you need new inlet filter - it comes with "complete assembly" kit. If you are buying separate pump, there is chance, that they will not give you this. That's why it's better to buy complete kit.
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Fuel pump is located under the back seat. Just pull it up, to expose fuel pump cover.
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Remove (with screwdriver) this metal cover, and you will see the fuel pump.
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Release tank pressure (vacuum), leave it open during replacement procedure.
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Fuel pump is tight on position because of big plastic nut holding it. Spray a lot of some penetrating oil and wait a while.
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Start the engine, let it idle for a moment, and pull out the electric plug/connector on the pump. Engine will die, and there will be no pressure in fuel lines. Now you can gently remove fuel lines (remember where is IN and OUT).
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I have heard the horror stories about enormous problems with undoing plastic nut. Mine was easy to unscrew. I just tapped it with punch/chisel and it started to move.
If you have problem, try to use two chisels and hammers at the same time. If it fails, you will be forced do make, improvise your own SST (special service tool).
This (removing big plastic nut) is the one thing that can really go wrong - generally difficulty level of this job is 1 (one).
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Nut removed...
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Old fuel pump assembly removed. Be careful with this black rubber gasket. Clean it, keep it. During installation of new pump, gasket goes first into tank hole, then goes the pump.
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Now you can look into the tank. The is some dirt (dust, sand)...
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It is recommended to have low level of fuel during this procedure - it's easy to clean tank.
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You can find strange things inside - this is piece of wood...
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Mind the gasket mentioned somewhere above. Put it first, then gently place the new pump assembly into tank (be careful with level floater, don't break it or bend it).
Tight the plastic nut (you can lube it with the same penetrating oil used to removing it, or silicone grease/oil) by two hands only (no tools, no hammer punching).
Tight until pump assembly will stop moving, playing freely under the nut. It's enough to keep it in place and make it sealed. Put back fuel lines (mind IN/OUT), hoses. Connect electric plug and it's done, ready to test drive. Then fasten metal cover, put rear seat on it's place, and that's all. There is no need to make air-bleeding.
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Why there was hesitation (not enough fuel)? Because internal filter was clogged...
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One more important thing - never run on low fuel level ("E", "reserve"), especially in winter (when it's freezing), because water condensation inside tank can freeze and damage the pump (mine started to make whining sounds about 2-3 weeks ago, when temperatures were negative, about minus 10C in place where I live).
In the other hand, when it's really hot, pump needs to be cooled down - fuel acts like lubricant and coolant to fuel pump.

If you want to replace pump itself (not entire assembly), go ahead, but remember about filter also (inlet filter from this picture, in-line fuel filter outside tank is a different story).
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That's all. Little bit messy, but simple job.
If something isn't clear - sorry, English is not my native language.
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Old 30-12-2012   #1
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Re: Fuel pump assembly replacement (Punto 1,1 SPI)

good post just two positives to add
1st-----poor boiling water on the pump prior to trying to remove it as it softens it up making removal simpler
be aware of sparking anything
2nd these pumps are designed to be cooled by the petrol flowing through and round them so its not a good idea to run constantly on reserve, you will pick up detrious in the tank bottom and also cause the bearings to fail but im sure most people know this anyway
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Old 31-12-2012   #2
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Cool SPI 1 bar fuel pump assembly replacement (Punto 1994)

1) First - good idea, instead of using chemicals (like penetrating oil), pouring hot water on plastic nut, also can help to unscrew it (maybe even by bare hand, without tools).

2) Second - read carefully, before you comment.
Because...you wrote the same thing as me.
I have never "recommended" driving on low level. I did opposite!
I must quote myself...
Quote Originally Posted by pmx007pl
... - never run on low fuel level...
Quote Originally Posted by pmx007pl
... - fuel acts like lubricant and coolant to fuel pump.
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Old 31-12-2012   #3
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Re: Fuel pump assembly replacement (Punto 1,1 SPI)

how we say in my country
ah yes we listen before open gob
i praised your post and added to it
unlike you
who take sleight because it no fit you liking
read your post again big boy
Quote Quote:
Why there was hesitation (not enough fuel)? Because internal filter was clogged...
see
maybe if you hadnt left part of your brain in the tank (the wooden bit) and also taken the pump out sooner and cleaned the filter bag you wouldnt have needed new pump
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Old 04-01-2013   #4
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Re: Fuel pump assembly replacement (Punto 1,1 SPI)

Hmmm curious i am now

the punot is known to have a ""long life"" fuel filter....
When you look at it like that - is just the filter changeable?

Ziggy
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Old 02-02-2013   #5
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Re: Fuel pump assembly replacement (Punto 1,1 SPI)

Thanks for the walk-through with the pump,

I never got the plastic ring off mine.. Never considered running the engine + removing filler cap to equalise the pressures,
Gracias,
Charlie
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Old 11-02-2014   #6
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Re: Fuel pump assembly replacement (Punto 1,1 SPI)

i always drive on reserve fuel and water pump still works normally
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Old 27-03-2015   #7
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Re: Fuel pump assembly replacement (Punto 1,1 SPI)

Hi pmx007pl

Are you still active? can you help me with a question regarding my fiat panda?

tony
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Old 12-05-2015   #8
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Re: Fuel pump assembly replacement (Punto 1,1 SPI)

last activity was couple of years ago so gonna guess no...

Whats the question?
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Old 15-09-2015   #9
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Re: Fuel pump assembly replacement (Punto 1,1 SPI)

just changed the fuel sender on my doblo 08 1.4 petrol.same procedure just note on inserting the new pump there is a locating notch in the tank top ,which lines up with the insert on the pump push down with one hand to keep rubber seal in !!!whilst screwing on locking nut !! otherwise it will keep cross threading as the seal comes up
thanks for info & saved around 300 by using delphni pump rather than the orginal bosch
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Old 22-05-2016   #10
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Re: Fuel pump assembly replacement (Punto 1,1 SPI)

I had fuel pump trouble on my 1994 model 55, hesitating and not accepting full throttle, classic fuel starvation.

After looking around for a replacement I removed my own and blew it through with the air line, the muck that came out into the cloth filter in the base was considerable.

I refitted it and have had no further trouble.

Much of the muck was from the big rubber ring that was decomposing and falling into the bottom of the petrol tank.

And yes I did break the plastic nut despite making a decent adapter for a socket wrench to slacken it off, but I found that plastic nuts from several other makes will fit.

Lastly the plastic petrol pipes stress the inlet and outlet pipes to the pump and will in the end crack them causing a massive petrol leak. My cure was to slide a short length of copper tube down into each pipe with a coating of araldite. This strengthens the two pipes and makes a permanent repair.

Sincerely

Roland
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Old 1 Week Ago   #11
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Re: Fuel pump assembly replacement (Punto 1,1 SPI)

Quote Originally Posted by varesecrazy View Post
Thanks for the walk-through with the pump,

I never got the plastic ring off mine.. Never considered running the engine + removing filler cap to equalise the pressures,
Gracias,
Charlie
UPDATE - got to do a mk2 sporting ..

removed tank from car for welding.... so cleaned out tank


this guide was a great help.. tapped the plastic "ring-nut"
undone without issue
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