Fuel Pump Replacement w/ non-Rover Pump

Lake_Bueller

Well-known member
Aug 11, 2004
2,105
59
56
Beloit, WI
MUSKYMAN said:

:bigok:

This brings me to a thought on "board improvement".

There is already a tech section on the main page. Why not have a "sticky" title Frequently Asked Questions. Then provide links in the sticky back to the tech section. This might save some web space with a million repeat questions about how to replace a fuel pump:applause:
 

PapaJoe

New member
Oct 11, 2010
4
0
I found this forum while looking for a fix for my fuel pump in my 99 D1. You saved me $750.

I was quoted $850 to fix this from the shop AAA towed me. After some research and finding this AWESOME thread, I went to Advance, got the pump, a sock and injector line. The guy at Advance gave me the line for free since it was less than a foot and it's sold by the foot. $100 out the door.

Took the parts to the parking lot behind the garage where my Disco was sitting and did the swap in 20 minutes. It took longer to unscrew and replace all the phillips heads than anything else. Didn't even need the injector line - the flange on the old pump was the same as the new one so I left the original accordian line on there.

$100, a phillips and my shoe (to smack the driver getting the ring off).

Thank you SO much for this thread!
 
ajh said:
That reminds me, I really should do the through-the-tub (properly) mod for the Defender to make this a little easier to do, dropping an extended range tank to change a pump has got to suck.

Expect to break all the hardware holding the skidplate/fuel tank cradle in place.

I have yet to remove a Defender fuel tank without breaking most, if not all of the hardware.
 

dan_t

New member
May 28, 2012
2
0
[English] BC, Canada
Reading this thread its come to my attention that the 96 4.0 is listed as having a different part number than other 4.0's? I checked the parts page but I only see 1 listing for 4.0 fuel pump.


Any ideas?
 

fishEH

Well-known member
Jan 26, 2009
6,929
203
Lake Villa, IL
dan_t said:
Reading this thread its come to my attention that the 96 4.0 is listed as having a different part number than other 4.0's? I checked the parts page but I only see 1 listing for 4.0 fuel pump.


Any ideas?
The actual pump(smaller than the size of a can of Coke) should be the same for all years. The pump housing will be different depending on if the truck is AEL or not.
 

montej

Member
Sep 29, 2013
15
0
Everett WA.
Great write up. I wish it was done last week. I had 10psi at the rail and disco running like crap. tested psi and started search for replacement pump. found 98' disco 2 pump. now I had to do some heavy mods cutting down the pump housing (not sending unit housing) to get to the pump but pretty much followed your procedure, now getting 38 psi static (key in position II) and 41 psi with engine at idle. Now disco runs much better, drinking more gas now that all 8 cylinders are firing correctly but i'm happy with the trade off. Now just watching for other things that they are noted for, like head gasket issues.
MonteJ
98' Disco I
 

1920SF

Well-known member
Jan 6, 2007
2,705
1
NoVA
Great write up. I wish it was done last week. I had 10psi at the rail and disco running like crap. tested psi and started search for replacement pump. found 98' disco 2 pump. now I had to do some heavy mods cutting down the pump housing (not sending unit housing) to get to the pump but pretty much followed your procedure, now getting 38 psi static (key in position II) and 41 psi with engine at idle. Now disco runs much better, drinking more gas now that all 8 cylinders are firing correctly but i'm happy with the trade off. Now just watching for other things that they are noted for, like head gasket issues.
MonteJ
98' Disco I

who sold you a 98 Dii pump?
 

best4x4

Well-known member
Mar 1, 2015
595
72
Beaumont, TX
Just to clarify 100% this mod works on AEL fuel pumps as well. I just did it today and I grabbed a Delphi pump and strainer from Auto Zone. I used 1/4 Fuel Injector hose rated at 250PSI, and I also used two 13-15mm Fuel Injector Hose Clamps. Quick and easy install/mod. When I tore my 10/97 OEM fuel pump apart the strainer was basically in pieces. I also installed the little rubber insulator around the fuel pump since I had plenty of room for it.

D1 runs great and I saved a lot of $$$ vs having to buy a complete AEL Fuel Pump Assembly. Just wanted to update this thread in case anyone else with an AEL Fuel Pump was curious if the install/mod worked.
 

97GreenMeanie

Well-known member
Mar 24, 2014
48
0
ny
Sorry to dig up this zombie thread..

Has anyone gotten an Engine light after replacing the LR pump with the chevy in a AEL Disco?

My 97 Disco died in traffic yesterday. Just stalled out and refused to start.
Cranked fine.

My 97 has the AEL and is giving me 10psi at the fuel rail when kicked to accessory.
I think the pump and filter is probably dead.
No evidence of it ever being changed and I'm at just shy of 145k.
Oh and I have a P0451 as well. No other codes, and not triggering engine light.

Not sure if I should replace the entire AEL fuel pump unit or swap in the chevy pump.
I cannot pass inspection with a CEL on in NY, I'm not due until April 2017 however.
 

jastutte

Well-known member
Nov 10, 2009
468
75
the ECU doesn't care what pump is in there as long as the fuel pressure is within spec. so, shouldn't have any issues using the chevy/gm pump.