Fuel Pump (FP) Unit and Sender For Fuel Gauge As of 07.03 - Component Overview
Fuel Pump (FP) Unit And Sender For Fuel Gauge As Of 07.03 - Component Overview
1 - Fuel Level Sensor -G-
2 - Fuel pump
- Check Fuel Pump (FP) electrically
- Checking fuel delivery
- Checking residual pressure, vehicles as of 07.03
3 - Seal
- To install, place into opening of fuel tank when dry
4 - Fuel return line
- From fuel filter
- Mark before removing
- To disconnect, press release button on connection piece
- Do not bend
- Note direction of arrow (fuel supply or return) on connector flange when installing
- Clipped in on fuel tank
5 - Ventilation line
- From fuel pressure regulator in fuel filter
- To disconnect, press release button on connection piece
- Do not bend
- Clipped in on fuel tank
6 - Fuel supply line
- To fuel filter
- Mark before removing
- To disconnect, press release button on connection piece
- Do not bend
- Note direction of arrow (fuel supply or return) on connector flange when installing
- Clipped in on fuel tank
7 - Electrical harness connector
- For Fuel Pump (FP) and Fuel Level Sensor -G-
8 - Locking ring
- Use wrench for tank sensor 3087 to remove and install
- Tighten to 145 Nm
9 - Suction jet pipe
- To disconnect, press release button on connection piece
10 - Vacuum booster
Fuel pump, removing and installing
CAUTION: To remove the Fuel Pump (FP), the fuel tank may only be filled to a maximum of 3/4. Empty fuel tank if necessary.
Recommended special tools and equipment
- Wrench 3087 for tank sensor - vehicles as of 07.03
- Wrench 3217 for union nut - vehicles up to 06.03
- VAS5190 fuel siphoning device
Empty fuel tank
Observe safety precautions.
Observe rules for cleanliness.
CAUTION: For vehicles with Telematics, activate service mode of the control module before disconnecting the battery.
- Note and if necessary, determine radio code for vehicles equipped with coded anti-theft radio / radio navigation system only foreign brands).
- Switch ignition off.
- If installed, slide cover over the battery to the right (arrow -1-) and pull it off upward (arrow -2-)
- With ignition switched off, disconnect Battery Ground (GND) wire (arrow).
CAUTION: Secure Ground (GND) wire of VAS5190 to a blank portion of the chassis.
- Pull cone piece -2- from shaft piece -1- of VAS 5190.
- Using insulating tape, apply a mark (arrow) on hose at length a = 1465 mm from end of suction hose.
- Remove fuel filler cap from fuel filler tube.
- Screw shaft piece -1- of VAS 5190 fuel siphoning device on to fuel filler tube of fuel tank.
- Slide suction hose as far into fuel tank until the mark applied earlier -arrow- stands on shaft piece.
NOTE: If using a siphoning device without shaft piece, proceed in the same manner.
- In this case, apply a mark -arrow- on hose at length a = 1400 mm from end of suction hose using insulating tape. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube.
- If the hose can only be inserted with difficulty, smear it thinly with engine oil. Never use lubricants containing silicon.
- Drain fuel tank through fuel filler tube.
- Carefully remove siphoning hose.
Removing
Limousine:
- Remove luggage compartment lining.
- Push forward right backrest of rear seat, if necessary.
Avant:
- Remove left 1/3 backrest.
- Remove left side trim in luggage compartment and dirt tray.
All:
- Remove cover for connector flange (arrows).
Vehicles up to 06.03:
- Release and disconnect harness connector -1-.
- Disengage electrical harness connector -2- and lay it aside.
WARNING: Fuel system is under pressure. Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
- Mark and disconnect fuel supply line -1- and fuel return line -2- (press release tab).
- Use ring nut spanner 3217 to remove union nut.
- Lift out fuel pump with sealing ring slightly from opening of fuel tank
Vehicles as of 07.03:
- Disconnect electrical harness connector -1- at connector flange.
- Disengage electrical harness connector -2- and lay it aside.
WARNING: Fuel system is under pressure. Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
- Mark and disconnect fuel supply line -1- and fuel return line -3- (press release tab).
- Disconnect ventilation line -2- (press release button).
- Remove locking ring using wrench 3087 for tank sensor.
- Lift Fuel Pump (FP) unit slightly out of fuel tank opening and remove sealing ring.
All:
- If Fuel Pump (FP) is still inserted in fuel tank, slide connector flange slightly to the side.
- Grasp through the gap between connector flange and installation opening in fuel tank and release suction jet pump -1-.
NOTE: Fuel tank is depicted as cut-out section.
- Pull suction jet pump -1- upward with suction jet pipe -2- still connected.
- Disconnect suction jet pipe from suction jet pump (press release button).
- Remove suction jet pump.
- Remove Fuel Pump (FP).
Installing
Installation is in reverse of removal. Note the following:
- Connect suction jet pipe -2- to connection for suction jet pump -1-.
- Insert Fuel Pump (FP) into fuel tank.
- Clip in suction jet pump -1- on Fuel Pump (FP). To do so, insert hand into gap between connector flange and installation opening of fuel tank.
- Suction jet pump must engage audibly
Vehicles up to 06.03:
- Insert new, dry seal for connector flange into opening of fuel container.
- Note installation position of Fuel Pump (FP):
- Marking on connector flange -2- must align with marking on fuel tank -1-.
- Tighten union nut for connector flange.
- Install fuel supply line -1- and fuel return line -2- according to marking.
Vehicles as of 07.03:
- Insert new, dry seal for connector flange into opening of fuel container.
- Press connector flange down against spring pressure and bring connector flange into installation position.
- Note installation position of Fuel Pump (FP):
- Tab -2- on connector flange must lie between tabs -1- and -3- on fuel tank.
NOTE: (Arrow) points in direction of travel.
- Tighten locking ring.
- Install fuel supply line -1- and fuel return line -3- according to the marking.
- Install ventilation line -2-.
All:
- Connect electrical harness connector.
Tightening torques
Union nut for Fuel Pump (FP) 80 Nm
Locking ring for Fuel Pump (FP) 145 Nm
Battery terminal to battery post 6 Nm
Final procedures
After re-connecting the voltage supply, the following work steps must be performed in the mentioned sequence:
1. Check DTC memory.
2. If necessary, erase DTC memory.
3. If DTC memory was erased, generate readiness code.
- End diagnostic.
- Activate vehicle equipment (radio/radio-navigation system, clock, electric window regulator), See Operating instructions
- Deactivate service mode of Telematics control module in vehicles with Telematics.
- Check radio-frequency remote control for function, synchronize radio-controlled key if necessary. Inform the customer that second and additional keys must also be synchronized to make sure radio-frequency remote control is functioning, See Operating instructions