Fuel Pump: Service and Repair

16 14 010 - Removing and installing/replacing fuel pump(s) (diesel)





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





For vehicles with 2 seat rows only:
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).





Release completely remainder of torque breakoff head (1) with a screwdriver.
Remove hose clamp from clamping ring (2).

Note:
A flexible extension can be used to release the hose clamp,

Press clamping ring (2) part at open end in direction of arrow 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 clip with torque breakoff head (4) must always be replaced.
Tighten hose clip until torque breakoff head (4) breaks off.





Installation:
Seal (1) must always be replaced.





Carefully raise service cap (1).
Unclip plastic tube (2).
Unlock and detach quick-connect couplings (3).
Remove fuel pump.

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