Fuel Pump: Service and Repair

Removing, Installing Fuel Pump










DANGER:
- Risk of explosion due to igniting fuel, risk of poisoning due to inhaling and consuming fuel and risk of injury due to fuel coming into contact with the skin and eyes.
- Fire, sparks, naked flames and smoking prohibited.
- Only pour fuel into suitable and appropriately labeled containers.
- Wear protective clothing when handling fuel.

1 Disconnect and connect the ground cable at the battery

NOTE: Installation:
- After connecting the ground cable, read out error memory, encode radio and calibrate power window
- Vehicles with stationary heater: set stationary heater clock.

2 Remove trunk cover (1)
3 Remove cover (2)
4 Ascertain as-build condition
- Fuel line with banjo bolt at fuel pump.

5 Unplug connector (5)
6 Press rubber grommet (4) out of floor panel

NOTE: Installation: Check rubber grommet for damage and correct installation.

CAUTION: If damaged: replace rubber grommet.

7 Remove cover (5) of fuel pump

NOTE: Unscrew the three nuts of cover through holes (arrows).

8 Remove cable strap (6) and clip (7)
9 Unclip fuel lines (8, 9, 10)
- See Special Tools below.

10 Pull fuel lines (8,9,10) off fuel pump (M3)

NOTE: Installation: Replace hose clips (11).

11 Loosen bolt(12)
12 Remove fuel pump (M3) in direction of arrow

NOTE:
Removal:
- Do not damage the insulation of the cable and plug of connector (3) when pulling through floor panel.
Installation:
- Check plastic sleeve (13) for damage.
- If damaged: replace plastic sleeve (56a).
- The plastic sleeve (13) must overlap on both sides of the bracket (14) since corrosion may occur if the fuel pump touches the bracket directly.

13 Install in reverse sequence

Special Tools: