Suction Jet Pump In Left Fuel Tank Chamber, Remove/Install

Suction Jet Pump In Left Fuel Tank Chamber, Removing And Installing

Special tools and equipment







- Wrench for fuel tank sender unit 3087







- Fuel pump wrench 3307


NOTE: This section describes how to remove the suction jet pump in the left fuel tank chamber. The suction jet pump in the right fuel tank chamber is part of the baffle housing and cannot be replaced separately.


- To remove the suction jet pump, the fuel tank must not be more than 1/4 full. Empty fuel tank if necessary.


WARNING: Observe safety precautions when disconnecting the battery.


- With ignition switched off disconnect battery ground strap.
- Open fuel filler cap briefly, then close it again.
- Remove rear seat bench.







- Detach cover for flange -arrows- (right side).







- Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
- Disconnect electrical harness connector -2- and set it aside.


WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.







- Disconnect fuel supply pipe -1- from locking flange (right side of vehicle).
- Disconnect breather pipe -2- (press release button).


CAUTION: The locking flange must only be opened with the fuel tank not more than 1/4 full. Otherwise a great amount of fuel flows out.







- Remove locking ring using wrench for fuel tank sender unit 3087.
- Remove flange and seal out of opening in fuel tank.







- Disconnect connector -arrow- for fuel gauge sender on inside of flange.







- Insert fuel pump wrench 3307 through opening in fuel tank and apply wrench to fuel delivery unit.
- Turn fuel delivery unit counterclockwise as far as it will go (approx. 15 degrees).







- Notch -1- will then be aligned with marking -2- (bayonet fitting).

- Take out fuel delivery unit.







- Detach cover for flange (left side) -arrows-.







- Carefully disengage and remove electrical harness connector (arrow) (left side of vehicle).


WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.







- Disconnect return line -arrow- from flange (left side of vehicle).







- Remove locking ring (left side of vehicle) using wrench for fuel gauge sender unit 3087.
- Carefully pull flange with fuel gauge sender II a short distance out of fuel tank opening together with seal.







- Pull fuel pipe -1- out of fuel tank.
- Swivel flange -2- with fuel gauge sender II -3- and suction jet pump -4- out of fuel tank opening.


NOTE: Take care not to bend the arm of the float when removing fuel gauge sender II.


- Unclip suction jet pump from flange with fuel gauge sender II.







- Press release catches -arrows- and disconnect fuel pipe at Y-connector.







- Pull fuel supply pipe -4- out of baffle housing.
- Press connecting piece -1- to the right and unclip it from baffle housing.
- Disconnect fuel return pipe -3- at connecting piece -1-.


NOTE: Fuel pipe -2- remains connected.


- Reach into fuel tank opening on left side of vehicle and pull out suction jet pump with lines towards the left.

Installing
Install in reverse sequence; note the following points:
- Push suction jet pump (with lines fitted) into fuel tank opening on left side of vehicle.
- Reach into fuel tank opening on right side of vehicle and pull suction jet pump with hoses into their final position.







- Press return pipe -3- onto connecting piece -1- so that the hose connectors engage.
- Clip connecting piece onto baffle housing.
- Fit fuel supply pipe -4- into corresponding hole in baffle housing.
- Clip suction jet pump onto flange of fuel gauge sender II and attach fuel pipe to Y-connector.
- Swivel flange with sender II and suction jet pump out of fuel tank.







- Note fitting position of flange of fuel gauge sender II:
- Lug -2- on flange must be between tabs -1- and -3- on fuel tank.


NOTE: Arrow points in direction of travel.







- Tighten locking ring (145 Nm).







- Fit fuel delivery unit into baffle housing (in tank) so that notch -1- on fuel delivery unit is aligned with marking -2- on baffle housing.
- The fuel delivery unit should move down noticeably.







- Insert fuel pump wrench 3307 through opening in fuel tank and apply wrench to fuel delivery unit.
- Turn fuel delivery unit clockwise as far as it will go (approx. 15 degrees).







- Notch -1- will then be aligned with marking -3- (bayonet fitting).







- Connect electrical connector -arrow- for fuel gauge sender on inside of flange.
- Fit new seal for flange in fuel tank opening (seal should be dry).







- Note fitting position of flange:
- Lug -2- on flange must be between tabs -1- and -3- on fuel tank.


NOTE: Arrow points in direction of travel.







- Tighten locking ring (145 Nm).
- Observe safety precautions after connecting the battery.

Tightening torques

Component Nm
Locking ring for fuel delivery unit or flange of fuel gauge sender II 145
Battery terminal to terminal post 6