Fuel Pump With Integrated Reservoir, Removing and Installing

Removing


NOTE: Follow safety precautions Vehicle Damage Warnings


CAUTION!
Before disconnecting the battery, determine the correct coding for the anti-theft radio.


- Disconnect battery Ground strap.
- Remove cover for fuel pump and fuel level sensor.
- Remove luggage compartment trim.







- Disconnect harness connector for fuel pump and fuel level sensor.
- Relieve system pressure by carefully opening fuel supply line.
- Disconnect fuel supply and fuel return lines.
On vehicles equipped with auxiliary heater, the supply line to the fuel pump is connected to mounting tube -A-.







- Using special tool 2012A, open fuel level sensor cover by turning clockwise, then remove compression spring below.







- Using pliers, carefully lift sensor and disconnect electrical harness connector.
- Remove fuel level sensor.







- Use special tool 3342 to open fuel pump lock ring.







- Loosen mounting tube (13 mm) and leave inserted.
- Press firmly on mounting tube to separate fuel pump with integrated reservoir from intake housing in fuel reservoir.
- Remove mounting tube.
- Remove fuel pump with integrated reservoir.
Pull and turn clockwise at the same time to remove pump from fuel tank.


NOTE: The illustration shows a cut-away view of how the fuel pump with integrated reservoir is installed in the fuel tank.


Installing


NOTE:







The illustration shows a cut-away view of how the fuel pump with integrated reservoir is installed in the fuel tank.


Before installing:
- Remove fuel from right cavity of fuel tank.
- Check connection between filler tube and integrated reservoir.
- Visually inspect integrated reservoir and connectors to transfer pump lines.

Installation is in reverse order of removal.


CAUTION!
After the installation, the integrated reservoir should be checked for leaks as described below. If a leak test is not conducted, add approx. 3 liters (3/4 gal.) of fuel before starting the engine, to pre-fill the reservoir.


Leak testing
- Add approx. 3 liters (3/4 gal.) of fuel and let engine run for 10 mm. Stop engine and let vehicle stand for approx. 6 hours.
If the engine starts without a problem after 6 hours and runs for 10 minutes without problems, the integrated reservoir is leak-tight.