Fuel Pump: Service and Repair

16 14 010 - Removing and installing/replacing fuel pump (gasoline vehicles)





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.
Contaminants in the fuel tank can impair driving operation or may even result in vehicle breakdown!
Before starting the engine for the first time:
- Fill fuel tank with at least 5 liters of fuel
Check transfer function of suction jet pump Testing and Inspection.





Necessary preliminary tasks:
- Draw off fuel from fuel tank Procedures
- Remove rear seat bench





If necessary, disconnect plug connection (1).
Remove cover (2).





Release nuts (1) and remove cover for service opening (2) from right side of fuel tank.





Disconnect plug connection (1).
Unlock quick-release fastener (2) and detach vent line.
If necessary, unlock quick-release fastener (3) for fuel feed line of independent heating and detach.
If necessary, disconnect plug connection (4) for independent heating fuel pump.





Measure gap dimension (A) at clamping ring (1).
Release hose clamp (2) and remove from clamping ring (1).
Press clamping ring (1) apart at open end and remove.





Installation:
Make sure that service cover is installed in correct position.
Indentation (2) on clamping ring must line up with raised section (1) of tank.
Pin on service cover (3) must line up with indentation on clamping ring.
Hose clamp (4) must always be replaced (pay attention to correct position).
Tighten hose clamp until clamping ring gap dimension is obtained.





Installation:
Seal (1) must always be replaced.





Disconnect grounding cable (1) towards top.

Important!
Grounding cable (1) must be replaced if it has been detached once!





Carefully raise service cover.
Unclip plastic tube (1).
Unlock and disconnect quick-connect coupling (2).
Remove fuel pump.

Important!
Catch escaping fuel in suitable container.
No fuel is permitted to get into the interior!





With fuel pump removed, disconnect plug connection (1) and replace grounding cable (2).