Pump reassembly. I purchased a new pump and installed it. Got machine back together and I'm not getting any pressure. What would be the signs if I don't have the shaft key in properly? Or any other suggestions?

its a matter of removing components out of the way until you can get all the pump bolts out. clean the block surface before you install the new pump. Reverse procedure to reassemble the engine.

No pressure would be a sign that the key was not in properly.

I recently purchased a refurbished EM-200 and it did not work and leaked water all over the place right out of the box. Without doing anything water leaked out of the bottom of the machine. When I tried to run the machine you can hear the pump but no water ever came out and after a few seconds it quite and the lights would start flashing and beeping.

The mechanical engineer in me just had to solve the problem. I unscrewed and removed the bottom plastic cover (3 screws) where the power card goes into the machine and found the problem. The water from the reservoir feeds into a white plastic priming pump. This priming pump is assembled in two halves and one half has four plastic clips that hold the pump together. In between the two halves is a rubber o-ring. Well, one of the clips was not secured and I could see part of the o-ring protruding. This is an obvious source of leakage. Either the pump was not properly assembled or it snapped out of place during shipping.
I unscrew the two screws that hold the priming pump in place, leaving the hoses attached, and carefully pulled the two pieces apart. Note how the magnetic impeller is installed and reassemble the same way. Use a small amount of vegetable oil to lubricate the o-ring and reinstall in the same place. Reassemble the to two halves, making sure the o-ring doesn't protrude, then snap the two halve together tightly. Screw the primer pump back into place then screw the bottom plastic cover back into place.

After this fix the machine no longer leaked and it brewed a nice espresso. Everyhing seams to work find now.

1. You only should have one check valve; the one in the water is best, remove the other if you can.
2. Make sure there are no leaks in any of the piping between the water and the pump inlet.
3. Take the pump apart, thoroughly clean the new seal, the two halves of the pump that go under the metal band, the inside of the metal band.
4. Lubricate the new seal, the outer sides of the pump halves where the metal band squeezes together, the inside of the metal band where it contacts the halves and even the screw on the tightening device using petroleum jelly (Vaseline) or equal. Make sure the pump literature does not recommend against whatever you use.
5. Reassemble.
6. Fill the pump with water, open the discharge on top of the pump if possible and prime.
Normally, a pump, even with a long run will prime in 5 minutes or less.

Write back.
Your FixYa Texpert,
Gary

Electric Fuel Pump-Fuel Injected REMOVAL & INSTALLATION The electric fuel pump is contained within the fuel tank. On 1988-92 models, it is necessary to remove the fuel tank from the vehicle in order to reach the pump. On 1993-97 models, the fuel pump can be accessed by removing the rear seat cushion and service hole cover. 1988-92 Models Fig. 1: Exploded view of the electric fuel pump
NOTE: Before disconnecting fuel system lines, clean the fittings with a spray-type engine cleaner. Follow the instructions on the cleaner. Do not soak fuel system parts in liquid cleaning solvent. CAUTION
The fuel injection system is under pressure. Release pressure slowly and contain spillage. Observe "no smoking/no open flame'' precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.

1. Disconnect the negative battery cable and relieve the fuel pressure. Remove the filler cap.
2. Remove the fuel tank from the vehicle.
3. Remove the fuel pump bracket attaching screws, then remove the fuel pump/bracket assembly from the tank. Fig. 2: Remove the bolts retaining the pump bracket to the fuel tank
   
   
4. Pull the lower side of the fuel pump from the bracket.
5. Remove the nuts attaching the wires to the fuel pump.
6. Disconnect the hose from the pump.
7. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip. Fig. 3: Pull off the lower portion of the pump from the bracket
   Fig. 4: If necessary, remove the clip and pull out the filter to replace it
   
   
8. While the tank is out and disassembled, inspect it for any signs of rust, leakage or metal damage. If any problem is found, replace the tank.
9. Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
10. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration. To install:
    
11. Install the pump filter using a new clip. Install the rubber cushion under the filter.
12. Connect the outlet hose to the pump, then attach the pump to the bracket.
13. Connect the wires to the fuel pump with the nuts.
14. Install the fuel pump and bracket assembly onto the tank. Use new gaskets.
15. Install the fuel tank.
16. Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.

1993-97 Models CAUTION
The fuel injection system is under pressure. Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times. Fig. 5: Exploded view of the fuel pump components

1. Disconnect the negative battery cable. CAUTION
   On models with an airbag, wait at least 90 seconds from the time that the ignition switch is turned to the LOCK position and the battery is disconnected before performing any further work. Refer to Section 7 for all air bag warnings.
   
2. Relieve the fuel pressure.
3. Remove the rear seat cushion.
4. Remove the floor service hole cover. Fig. 6: Remove the 4 service hole cover retaining screws
   
   
5. Disconnect the electrical fuel pump wiring at the fuel pump assembly. Check for any fuel leakage while in there.
6. Remove the gas cap, this will prevent any fuel gas spilling out of any high pressure lines.
7. Using SST 09631-22020 or an equivalent line (flare nut) wrench, disconnect the outlet pipe from the pump bracket. Fig. 7: Disconnect the outlet pipe from the pump bracket
   
   
8. Remove the pump bracket attaching screws.
9. Disconnect the return hoses from the pump bracket, then pull out the pump/bracket assembly.
10. Remove the nut and spring washer, then disconnect the wires from the pump bracket.
11. Remove the sending unit attaching screws, then remove the unit from the bracket. Fig. 8: Pull the pump bracket with pump attached from the tank
    
    
12. Pull the lower side of the fuel pump from the bracket.
13. Unplug the connector to the fuel pump.
14. Disconnect the hose from the pump.
15. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
16. Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
17. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration. To install:
    
18. Install the pump filter using a new clip. Install the rubber cushion under the filter.
19. Connect the outlet hose to the pump, then attach the pump to the bracket and tighten to 22-25 ft. lbs. (29-34 Nm).
20. Engage the connector to the fuel pump.
21. Install the fuel sending unit to the pump bracket.
22. Install the fuel pump and bracket assembly onto the tank. Use new gaskets. Tighten the pump bracket retaining screws to 34 inch lbs. (4 Nm).
23. Connect the return hoses to the pump bracket.
24. Install the service hole cover, then the engage the fuel pump and sending unit connector.
25. Install the rear seat cushion.
26. Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.

Hi Adam just found your posting,Do you still need help?If you do reply back and I will help you rectify this fault.Looking forward to your reply.

1992-96 Models
See Figure 6
Be sure this procedure is done in a well ventilated area.

1. Disconnect the negative battery cable.
2. Relieve the fuel pressure.
3. Remove the rear seat cushion.
4. Remove the floor service hole cover.
5. Disconnect the electrical fuel pump wiring at the fuel pump assembly. Check for any fuel leakage while in there.

fuel pump and sending unit cover

1. Remove the gas cap, this will prevent any fuel gas spilling out of any high pressure lines.
2. Using SST 09631-22020 or an equivalent line (flare nut) wrench, disconnect the outlet

pipe from the pump bracket.

1. Remove the pump bracket attaching screws.
2. Disconnect the return hoses from the pump bracket, then pull out the pump/bracket assembly.
3. Remove the nut and spring washer, then disconnect the wires from the pump bracket.
4. Remove the sending unit attaching screws, then remove the unit from the bracket.
5. Pull the lower side of the fuel pump from the bracket.
6. Unplug the connector to the fuel pump.
7. Disconnect the hose from the pump.
8. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
9. Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
10. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.

To install:

1. Install the pump filter using a new clip. Install the rubber cushion under the filter.
2. Connect the outlet hose to the pump, then attach the pump to the bracket and tighten to 22-25 ft. lbs. (29-34 Nm).
3. Engage the connector to the fuel pump.
4. Install the fuel sending unit to the pump bracket.
5. Install the fuel pump and bracket assembly onto the tank. Use new gaskets. Tighten the pump bracket retaining screws to 34 inch lbs. (4 Nm).
6. Connect the return hoses to the pump bracket.
7. Install the service hole cover, then the engage the fuel pump and sending unit connector.
8. Install the rear seat cushion.
9. Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.

Check the drain hose and clear it from any debris that might be blocking the water from draining out completely. If the drain hose is clear of debris, check and clean the pump. Disconnect the machine from the power outlet before servicing for safety purposes.

Remove the rear access panel to access the pump and disconnect the wiring harness from the terminals of the drain pump and the pressure switch.

Loosen the clamps holding the drain hose and the tub hose to the pump assembly. It is a good idea to spread a towel under the pump before loosening the clamps.

Remove the hoses and rotate the pump assembly counterclockwise to release the pump assembly support legs from the keyed slot in the base of the washer. Remove the pump assembly from the washer.

Clear the pump impeller from any debris that might be causing it to work improperly. Clean the tub and the drain hose.

Reassemble the pump, the hoses, and reconnect the wires to the terminals of the pressure switch and the drain pump. Reinstall the rear access panel and run the machine.

Replace the pump (part #25001052) if water still do not drain out completely.

Remove the plastic bag covering the pressure switch. Press in the locking tabs on the back of the pressure switch and pivot the pressure switch off the pump bracket.

Grasp the pressure switch and lift the nipple of the pressure switch from the pump cap.

Install the pressure switch into the new pump assembly in reverse of the steps above.

Fuel pump is located inside the fuel tank and is attached to the sending unit. Do not smoke or have any open flame in the work area when removing the fuel pump.

REMOVAL OF FUEL PUMP:

1. Disconnect the negative battery cable.
2. Relieve fuel pressure
3. Remove the rear seat cushion.
4. Remove the floor service hole cover .
5. Disconnect the electrical fuel pump wiring at the fuel pump assembly. Check for any fuel leakage while in there.
6. Remove the gas cap, this will prevent any fuel gas spilling out of any high pressure lines.
7. Use a fare nut wrench to disconnect the outlet.
8. Remove the pump bracket attaching screws
9. Disconnect the return house from the pump brackets, then pull ou the pump/bracket assembly.
10. Remove the nut and spring washing, then disconnect the wires from teh pump bracket.
11. Remove the sending unit attaching screws then remove the unit from the bracket.
12. Pull the lower side of the fuel pump from the bracket.
13. Unplug the connector to the fuel pump
14. Disconnect the hose from the pump.
15. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
16. Inspect all the lines, houses and fittings for any sign of corrosion, wear and damage to the surfaces. Check the pump outlet hole and the filter for restrictions
17. When reassembling, ALWAYS replace the sealing gasket with a new ones. "Also replace any rubber parts showing any sign of deterioration".

To install:

1. Install the pump filter using a new clip. Install the rubber cushion under the filter
2. Connect the outlet hose to the pump and pump bracket.
3. Engage the connector to the fuel pump. Install the fuel sending unit to the pump bracket. The remainder of the installation is the reverse of the removal.
4. Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.

1992–96 Models NOTE: Be sure this procedure is done in a well ventilated area.

1. Disconnect the negative battery cable.
2. Relieve the fuel pressure.
3. Remove the rear seat cushion.
4. Remove the floor service hole cover.
5. Disconnect the electrical fuel pump wiring at the fuel pump assembly. Check for any fuel leakage while in there

Fig. 6: Pull back the rug under the rear seat to access the fuel pump and sending unit cover

1. Remove the gas cap, this will prevent any fuel gas spilling out of any high pressure lines.
2. Using SST 09631–22020 or an equivalent line (flare nut) wrench, disconnect the outlet pipe from the pump bracket.
3. Remove the pump bracket attaching screws.
4. Disconnect the return hoses from the pump bracket, then pull out the pump/bracket assembly.
5. Remove the nut and spring washer, then disconnect the wires from the pump bracket.
6. Remove the sending unit attaching screws, then remove the unit from the bracket.
7. Pull the lower side of the fuel pump from the bracket.
8. Unplug the connector to the fuel pump.
9. Disconnect the hose from the pump.
10. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
11. Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
12. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration. To install:
    
13. Install the pump filter using a new clip. Install the rubber cushion under the filter.
14. Connect the outlet hose to the pump, then attach the pump to the bracket and tighten to 22–25 ft. lbs. (29–34 Nm).
15. Engage the connector to the fuel pump. Install the fuel sending unit to the pump bracket.
16. Install the fuel pump and bracket assembly onto the tank. Use new gaskets. Tighten the pump bracket retaining screws to 34 inch lbs. (4 Nm).
17. The remainder of installation is the reverse of removal. Tighten each component to specifications. Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.

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