Fuel Pump: Service and Repair

16 14 010 Removing And Installing/renewing Fuel Pump (Diesel)

Special tools required:
- 16 1 020

Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
Observe country-specific waste-disposal regulations.

IMPORTANT:
Ensure adequate ventilation in the place of work.
Avoid skin contact (wear gloves).
Ensure absolute cleanliness when working on the open fuel tank.

Before starting the engine for the first time:
- Fill fuel tank with at least 5 litres of fuel.

Necessary preliminary tasks:
- Draw off fuel from fuel tank
Procedures
- Remove rear seat bench
Removing and Installing/Replacing Rear Seat (Through-Loading)

Release screws (1) and remove cover (2) from right side of fuel tank.

Disconnect plug connection (1).
If necessary, remove fuel line for independent heating.

Release screw cap with special tool 16 1 020 and remove service cap.

Installation:
Procedure for tightening screw cap, see next work step.

IMPORTANT:
Fit screw cap without using a tool and tighten hand-tight.
Then tighten screw cap with special tool 16 1 020 until notch (1) points to marking (2).

NOTE: Illustration shows the tank removed.

Pull out service cover (1).
Unlock and disconnect quick-release fastener (3) of fuel feed line.

Installation:
Clean sealing faces and install new rubber seal (2).
Locating rods (4) must fit correctly in the hole (5) of the delivery unit.
Make sure that the lever sensor moves freely before fitting the service cap (1).

Installation:
Service cap can only be installed in one position.

When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.

Disconnect line (1) towards top
Unlock quick-release fastener (3) and detach fuel return line (2).

IMPORTANT: Do not use any tools to release the fuel feed line.

Draw off remaining fuel from surge chamber.
Carefully lift fuel pump with fuel level sensor (4) out of fuel tank.