Talk Morgan Forums Morgan Sports Cars Classic Morgans (pre-CX) 4/4 zetec fuel pump problem.

Hello, the fuel pump on my 1998 4/4 is giving problems. It fails to work on trying to start. I’m thinking a replacement might be due. Looking at the pump from above there’s a wooden cross beam blocking access . It is possible to drop the fuel tank from below to facilitate repair? Has anyone done this and knows what is involved? Maybe a job for a garage?
Thanks, Chris

Have you tried fitting a new fuel pump relay?
That was the issue on my Zetec 4/4.
I now always keep a spare relay in the car.
Bud
4/4 - Stanley

The tank sits on wooden boards and can be removed but I would check the relays.

Can you not reach the pump by removing the parcel shelf panel behind the seats and then the tool tray if fitted?

Thanks for that. I’ve changed the relay and it clicks well when the ignition key is turned.
But there’s no sound from the pump priming. It’s an intermittent fault. Sometimes just leaving the car overnight in my garage and it will start as normal the next day although I’ve done nothing to it.
It’s rather annoying as it makes the car unreliable.

Have you checked that the wiring to the pump terminals is sound, a poor connection here could cause an intermittent fault? - as mine did.

Sounds like it's just a faulty connection somewhere, try running a temp feed from the battery (& the earth too as these are notoriously dodgy) and see if you get the pump running reliably first

I have a 1999 4/4 Zetec and the fuel gauge sender failed. That is also not possible to remove without removing the tank. Again a wooden body beam is in the way. To remove the tank the floorboards have to be removed and they slide forward. Unfortunately they wont slide forward because they foul on the back axle diff case. When I asked Morgan how to go about this, their solution was to put two 18 stone men sat on the back of the car and this pushes the floorboards below the diff, jam the rear suspension in this position with two blocks of wood jammed between the back axle and the chassis and then lift the car and continue to remove the floorboards. I felt that this was far too dangerous to attempt on axle stands. So I took my car to Mulfab. They saw through the floorboards along the edges, parallel to the chassis and refit them using a stainless steel fabricated frame that bolts to the chassis with three bolts either side. From then on removing the tank is simply a matter of removing the six bolts. They will supply the tank support frame through the post if you are up to doing the job but I felt that it was too dangerous for me so I got them to do it. Good Luck. Regards Tony

Thanks everyone for their suggestions.
Tony, the information you sent me is very useful. It would seem to be not very straightforward at all. A job for a professional. Unfortunately I’m nowhere near Mulfab. Maybe a Morgan dealer would take on this job?

Chris where are you?

I had a real saga with my pump on 2002 4/4 and had the fuel pump replaced (£1000!) but still failed and finally the dealer replaced the earth wire and had a direct connection as it was an intermittent fault. It seems to have solved the isssue now (fingers crossed 2 years now). The dealer did say the pump was faulty but I am not sure.....