Fuel Pump: Service and Repair

Removing And Installing Fuel Pump







NOTE: The fuel pumps have different hose connections and must not be confused.

Required tools

Item 1:

WARNING:
Danger of fire.
- Keep clear of ignition sources.
- Do not smoke.
- Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
- Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge.
- Danger of fire due to hot exhaust system. Always allow the exhaust system to cool down.
- Secure the vehicle, e.g. with a warning sign.
- Change any clothing soaked with fuel immediately.
- In case of fire, use CO(2) or dry powder fire extinguishers.

CAUTION:
- Please observe general warning notes and working regulations.
- For safety reasons, the tank should only be removed and installed when empty

NOTE: All windows should be opened for better ventilation in the passenger compartment.

1. Open filler flap.
2. Fold rear seat forwards.
3. Fold up the retaining brackets of the (right and left) belt anchor. To do so, undo the four fastening screws and fold up the bracket with the belt anchor. Do not use the fastening screws again.







4. Undo the caps (figure shows both). To do so, cut out the carpeted floor along the perforated lines using a carpet knife and fold it over. Then unscrew the four fastening nuts and remove the lid.






5. Empty the fuel tank.
6. Carefully remove the fuel supply -1- at the right connection unit and loosen the two disconnection points -2 and 3-. Also remove line (not shown here) in vehicles with auxiliary heating (auxiliary heater).







7. Disconnect all connections on the left connection unit.

CAUTION:
- Fuel vapours will penetrate the passenger compartment when you open the locking unit. Ventilate the vehicle well.
- Do not spill fuel into the passenger compartment.
- Ensure good ventilation when working on open fuel tank.
- Wear suitable protective equipment (breathing mask and protective gloves) when working on the tank.
- All seals must always be replaced.

NOTE:
- Replace the cap seal.
- If the tank must be opened for emptying, disconnect all connections.

Removing and installing left fuel pump
1. Open both caps with the key T10202 and lift up the pressure regulator unit (cap).







2. Disconnect the electric plugs -1 and 2-. Then pull off the fuel lines -3 and 4- and remove the pressure regulator.







3. Disconnect the sucking jet pump at the fuel pump. To do this, press on the left and right and pull off the connection.







4. Raise the right connection unit slightly and disconnect the fuel pump line at the Y-piece (on the right side).
5. Turn the pump approx. 90 degrees to the left until it disengages at the tank floor.







6. Remove the pump from the tank.
7. Place the pump in the holder on the tank floor and turn it approx. 90 degrees to the right until it is seated securely.
8. Connect the fuel line from the pump to the Y-piece (right side of the tank).
9. Connect the sucking jet pump connection. This must engage audibly.






10. Replace both seals on the connection units.







11. Connect connection unit. Connect the electric plugs for the fuel level sensor and fuel pump. Then push on the fuel lines. The connectors must engage audibly.







12. Place the connection unit into the tank. When doing so, make sure that the plastic lug is pointing forwards.

Removing and installing right fuel pump
1. Open the right cap with the key T10202 and lift up the pressure regulator unit (cap).







2. Disconnect the electric plugs for the fuel pump and fuel level sensor. Then pull off the fuel lines on the pressure regulator and remove the connection unit.







3. Disconnect the sucking jet pump at the fuel pump. To do this, press on the left and right and pull off the connection.







4. Disconnect the hose for the left fuel pump at the Y-piece.
5. Turn the pump approx. 90 degrees to the left until it disengages at the tank floor.







6. Remove the pump from the tank.
7. Place the pump in the holder on the tank floor and turn it approx. 90 degrees to the right until it is seated securely.
8. Connect the fuel line from the left pump to the Y-piece.
9. Connect the sucking jet pump connection. This must engage audibly.







10. Replace connection unit seal.







11. Connect connection unit. Connect the electric plugs for the fuel level sensor and fuel pump. Then push on the fuel lines. The connectors must engage audibly.
12. Place the connection unit into the tank. When doing so, make sure that the plastic lug is pointing forwards.

Closing the tank
1. Close the tank. To do so, fit the sheetmetal ring and tighten to a tightening torque of 140 Nm (104 ftlb.) using key T10202.







2. Fit all connections (fuel lines, ventilation tubes and electric plugs).







3. Fit lids. Tighten the four fastening nuts to 10 Nm (7.5 ftlb.). Refit carpeted floor and fix with double-sided adhesive tape.







4. Tighten the belt anchor fastening plates. Use three new fastening screws for this and tighten to 20 Nm (15 ftlb.).







5. Fold rear seat down again.
6. Refuel the vehicle.

Tightening torques