Fuel Pump/Tank Sender; To Remove/Refit Fuel Pump Assembly - Lotus Evora Service Notes

Lotus Service Notes
- If the engine is a non-runner, pull out the fuel pump fuse, and crank the engine for 20 seconds to minimise
residual fuel pressure.
- Disconnect the battery.
- The hose connecting the fuel tank to the fuel rail has no joints other than the push-on connectors at each
of its ends. For access to the fuel tank connection, the cabin rear compartment floor must be removed,
followed by the body and chassis access hatches. To access the fuel rail connection with the clamshell
fitted, it is necessary to remove the airbox.
- Surround the pipe joint with a shop towel to absorb fuel contained in the pipework before pressing the
release buttons and separating the joint.
WARNING: Be aware of the possibility of full pressure retention in the fuel line caused by a system
fault.
- On re-fitting, push the joint firmly together until a click is heard. Pull on the pipe to ensure complete en-
gagement.
LN.4 - FUEL PUmP/TANK SENDER
The fuel pump/gauge sender unit is mounted centrally in the front upper surface of the fuel tank, accessible
via removeable panels in the cabin rear compartment body floor and chassis. The modular fuel pump/gauge
sender assembly is mounted inside the tank, clamped to the top surface by eight studs. The pump uses an
electric motor to power an integrated turbine, to draw fuel through an intake strainer sock, and pump the fuel
through the motor body and a non-return valve, to exit into a filter chamber incorporated into the housing of
the pump/sender unit. After the filter, a pressure regulating valve controls the output line pressure to around
3.2 bar, spilling excess fuel back into the tank, and supplying the pressurised fuel to the outlet port on the top
surface. A non-recirculation type of fuel feed system is employed in order to minimise evaporative emissions.
Note that for some markets, a fuel tank pressure sensor for on-board diagnostics is fitted alongside the pump/
sender in the tank top surface.
The fuel gauge sender is mounted on the side of the pump housing, and uses a float on a pivoted arm to
operate two rheostat strips supplying fuel level data to the engine ECU.

To remove/refit fuel pump assembly

1. De-pressurise the fuel system (see sub-section LN.3).
2. Remove the cabin rear compartment floor covering, and the access panels in the body and chassis. Us-
ing an absorbent cloth to collect residual fuel, slide the yellow retaining clip aside and withdraw the pipe
from the pump spigot.
3. Unplug the harness connector to the pump and pressure sensor (if fitted).
4. Release the 8 fixings and withdraw the securing the clamp plate, noting the position of the earth lead.
5. Taking suitable precautions to catch any dripping fuel, carefully withdraw the pump assembly from the
tank aperture, taking care not to damage the delicate float arm, strainer sock, or other vulnerable parts.
6. Fuel pump: If necessary, the fuel pump may be removed from the housing by unclipping the yellow retainer,
removing the rubber cushion, unplugging the harness connector, and withdrawing the pump.
7. Before re-fitting, ensure that the strainer sock is clean, replacing if necessary, and using a new retaining
clip. Note that the non-return valve is incorporated into the outlet spout of the pump, and is not individually
replaceable.
8. PRV: The pressure regulator valve may be replaced after unclipping the yellow retainer from the base of
the housing, and withdrawing the valve.
9. Level sender: The fuel level sender unit may be removed from the housing by unplugging the connector,
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Section LN