Fuel Pump: Service and Repair
AR47.20-P-5713TK Remove/Install Fuel Pumps
Remove/Install
DANGER:
- Risk of explosion from hydrogen gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury to eyes and skin suffering caustic burns from battery electrolyte or from contact with damaged lead acid batteries.
- No fire, sparks, open flames or smoking.
- Wear acid-resistant gloves, clothing and glasses. Pour battery electrolyte only into suitable and appropriately marked containers.
1 Disconnect ground line of battery
NOTE:
- Turn key in electronic ignition switch EIS into position "0". key cannot be withdrawn.
- Vehicle fitted with code (889) Keyless-Go: Switch off engine, remove Keyless-Go cards from the vehicle and store outside of transmitter range
- Installation: After connecting, read out diagnostic trouble code memory, set time at instrument cluster, encode radio, normalize power windows and activate steering angle sensor.
- Vehicles with stationary heater: adjust time display on stationary heater.
DANGER:
- Risk of explosion if ignition takes place, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.
- Fire, sparks, open flames or smoking forbidden.
- Pour fuels only into suitable and appropriately marked containers.
- Wear protective clothing when handling fuel.
2 Pump fuel out of the right-hand chamber of the fuel tank
NOTE:
- Suction off approx. 20 L when fuel tank is full:
- Draining and filling fuel tank
3.1 Remove rear seat cushion
- Except the through-loading facility code (287a)
3.2 Place the rear seat cushion vertically
- In case of through-loading facility code (287a)
4 Spit back sound deadening mat
5 Disconnect electrical connectors
6 Screw on ring nut with claw-type wrench
- Claw-type wrench: See Special Tools below.
7 Separate fuel return line (3) from pump pots
NOTE: Press clutch and pull out fuel return line (see arrow).
8 Remove level line (2) of suction jet pump from pump pot
NOTE: Level line is used for adjusting fuel level of both halves of tank.
9 Slacken fuel feed lines (4) from fuel pumps
NOTE: Completely remove plastic damps (5).
CAUTION: Installation: Pay attention to the installation position of the plastic clamp The longer tabs of the plastic clamps must point toward top (direction fuel feed line). If installation position is incorrect the fuel feed line can loosen, the fuel supply is therefore no longer ensured.
10 Separate swirl pots (6)
NOTE: Slacken connecting pin (1), with screwdriver or by hand (see fig), from swirl pot and pull out.
11 Individually remove swirl pots (6) with fuel pumps and fuel level sensor
NOTE: Do not exchange fuel pumps individually, only in connection with fuel level sensor.
12 Install in the reverse order
Special Tools
Prong Wrench, P/N # 203 589 01 07 00:
