Heres some tips on how to stop the pumps from stuffing/jamming up.

I work in the spare parts industry (fuel injection, ignition and engine management mostly) and see these common things every day. I know that most of you know this, but for those that don't, you might want to learn.

1. never let the tank go to near empty. Not only does the pre pump suck in a lot of crap from the bottom of the tank, but it heats up the pump too, (as fuel is used to cool the pump internals down). When you then fill the tank up, the cold fuel goes through the hot armature of the pump and warps the body jamming it up and also possibly causing problems to the main pump that will run dry and seize. This can happen whether you have one or two pumps.

2. Never fill up at a servo (gas station for you yanks) that is refilling the tanks as you fill up or just prior to you filling up. When they refill the tanks it takes a while for the crap at the bottom of the service station tank to fall so you are pumping the dirt straight into your fuel tank and possibly causing the pump to jam.

3. When you fill up the cars fuel tank, always get a docket as if the station has a bad batch of fuel you can claim compensation for the price of a fuel pump replacement. I have done this once, and if you can prove that this is the case (if they get more than a few people complaining)they will compensate.

4***. If the fuel tank is jammed by rubbish getting into the armature and seizing it, the pump is not able to be replaced by warranty. the pump is checked at by an authorised person from Bosch (if it is a genuine bosch pump that is installed), and if any traces of foreign matter are found, no warranty is given. Otherwise, bosch pumps come with the standard 12 month warranty.

Always replace the pumps with Bosch items. They are better pumps than the garbagE REPLACEMENt items that last for 2 months and them fail. AND Always fit the pre strainer to the pump. It stops most of the dirt entering the pump.

Hope this helps.

Will323i