Lancia Delta Integrale specialists and enthusiasts
New fuel pump
An engine needs two things to run, fuel and a spark,
if your Delta won't go it's probably lack of one of those.
You can check for a spark at the plugs, and if there's fuel in the tank, you can check if the fuel pump works by disconnecting the fuel pipe at the engine and carefully trying the starter. Carefully(!) wiring the pump directly from a live feed will test the actual pump, if there are other electrical issues they will need to be dealt with. Check a page on this here.
If the pipe stays dry you'll need to get the pump out, it may be just a pipe has come off in the tank, or the pump may be faulty, but it needs to come out, here's how it's done.
The pump is located under the back seat. So fold the seats forward and remove the plastic dust sheet, then remove both side rear plastic sill covers, so you can roll the underseat carpet forward to clear
your work area
Undo the 8mm nuts securing the metal pump cover, give the area a quick clean so dirt doesn't go in the tank.
Remove the tank top pipe clamp and pull out the 2 fuel pipes, then remove the soft rubber gasket.
Undo the 8mm nuts securing the car body pipe clamps, including the 2nd clamp at the far end, and move
the pipes clear.
Before you disconnect the battery, remove the 2 pin plug to the pump, there's a small clip at the bottom, turn the ignition on and just check the voltage reading. Low voltage to the pump has the same effect as a failing pump.
Deltas are wired differently, so some run the pump first, and some don't run the pump until the engine turns, I'm not sure which model does which!
Then disconnect the battery, you do not want a spark!
Hammer off the plastic ring.
The pump and its top mounting are secured by a plastic ring, this has raised ribs on it. Use a worn flat screwdriver and tap the ring anti clockwise, it will then loosen.
Undo and remove it, the pump mounting top is a snug fit in the top tank hole, pull it upwards.
Attached to the pump, you'll find there's a copper pipe coil and rubber pipes, this makes the pump assembly difficult to lift out of its hole. It will come with some manipulation, but if it won't, you can remove the coil making room to pull the pump through its hole. Undo the rubber pipe at the pump top, and the outlet pipe at the mounting. Let it go and pull the pump out of its hole, you can get it out of the tank next.
It's a tight fit, and will take a bit of wiggling, but it'll come out, if you disconnected the coil collect it now.
Put the metal cover over the tank hole to stop anything falling in, then take the whole
unit to the bench.
Pull out the pump.
The pump from Tanc is a Walbro pump, this replaces the original. It's a smaller pump so it needs a wider rubber mounting,
this is supplied with the kit. I think the pump has a bit higher output than the old Bosch unit. Let's hope so!
On the bench, unclip the mounting blades and remove the plastic top, pull the old pump out of its swirl pot, undo the screws and remove the filter, give this a good clean.
Give inside the swirl pot a good clean too.
There's a plastic cap protecting the new pump intake, be sure to remove this!
Squeeze the pump into it's new rubber mounting, refit then squeeze this into the plastic casing.
The Walbro pump has spade fittings, you'll have to change the original bolt on fittings for spade clips, one is of course smaller than the other,
some kits include the new spade clips
Refit the filter and push the unit back into the swirl pot, don't forget the short vent pipe.
You don't really need to refit the curly copper pipe,
but be careful how you fit the new rubber hose, I've had them slide off the pipe once in the tank, and of course the car won't start.
Pushing the pipes into the plastic top can be tricky, the O rings are a tight fit. Carefully ease the rings down with a little screwdriver, be very gentle not to damage the seals.
Clip the mounting blades onto the swirl pot
and go to the car. If you retain the coil and you can get the whole assembly down the tank hole, do that. If you retained the coil and it won't go in complete, put the coil and pipes into the tank first, keep hold of an end, then drop the pump unit in, you'll have to refit the coil's rubber pipes now, with the unit in place.
Push the pump top down into its seal, then refit the top securing ring, the pipes should line up before tightening this, fit the rubber seal, then the pipe central securing clip.
Replace the pipe mounts and nuts, then refit the electric plug, check connections are safe and the top is clear of fuel, then connect the battery. Start the car to test the pump before you fix all the trim back on.
Then replace the metal cover, plastic sill cover and put the seat down,
the roadtest will be fun!
Do be careful, electric sparks and fuel are dangerous together!