Fuel Pump: Service and Repair

REPLACING FUEL PUMP(S):



- Draw fuel out of tank with scavenge pump, as far as possible at filler neck.

CAUTION: Conform to safety regulations as well as national legislation. Use suitable scavenge hose and twist slightly when inserting and when withdrawing.

Installation Note:
- Always use new hose clamps.
- Check fuel hoses for condition and leakage, replacing if necessary.




- Remove right-hand back seat.
- Unfasten screws.
- Remove right cover.




- Remove connector for fuel pumps (1).
- Remove connector for swing-arm fuel level sender (2).




- Remove fuel hoses.
- Draw off fuel vapors in car.

NOTE: Mark fuel hoses.
1. Intake pump 1 (cylinder bank 1...6)
2. Intake pump 2 (cylinder bank 7...12)




- Unscrew cap nut from fuel level sender unit on fuel pump using special 16 1 020.




- Carefully remove unit.

Installation Note:
- Press level sensor slightly into housing.




CAUTION: Always use new seal and new cap nut.




Installation Note:
- Always use new fuel strainer.
- Fit fuel strainer and allow to engage correctly.




Installation Note:
- Install seal, then swivel strainer and float into tank. Slide in unit upright, compressing level sensor and housing slightly as you do so.




Installation Note:
- Before pressing finally home, raise unit slightly (taking care of seal) end move gently to and fro to ensure that the level sensor is up-right in the correct area and that the float is able to move freely.




Installation Note:
- Before tightening the cap nut, ensure that the rib on the flange and the cast lug (protruding) on the tank point in the same direction. Note tightening torque of cap nuts.




- The sensor for the right fuel indicator forms one unit with the fuel pumps and the tank flange. This must be replaced as a complete unit.




Installation Note:
- Check fuel hoses and replace if necessary.
- Fit new hose clamps.