Fuel Pump: Service and Repair
Removing And Installing Fuel Pump
Tools
Tools:
Preliminary work
1. Empty the fuel tank.
Information
General note
NOTE: The fuel pumps have different hose connections and must not be confused.
Removing fuel pump
Opening the tank
NOTE: If the tank must be opened for emptying, disconnect all connections.
1. Open filler flap.
2. Fold rear seat forwards.
3. Fold up the retaining brackets of the (right and left) seat-belt buckles. To do so, loosen the four fastening screws and fold up the bracket with the seat-belt buckle. 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 if this has not already been done or if the fuel level in the fuel tank is very low.
DANGER: Danger of poisoning from fuels.
- Gasoline is toxic.
- Inhaling vapours can cause irritation of the mucous membranes and eyes.
- It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.
- Only work on the fuel system in well-ventilated rooms.
- Wear protective gloves that are fuel-resistant.
- Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
- Ensure that there is adequate ventilation and extract all fuel vapours.
- Before opening the fuel lines or fuel hoses, relieve the fuel pressure.
- Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
- Pay attention to cleanliness when working on the fuel system.
DANGER: Danger of fire from fuel.
- Keep clear of ignition sources.
- Do not smoke.
- Disconnect battery.
- 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. Allow engine to cool down.
- Secure the vehicle, e.g. with a warning sign.
- Change any clothing soaked with fuel immediately.
- In case of fire, use CO2 or dry powder fire extinguishers.
NOTE:
- The ignition must be switched off when working on the fuel system.
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurized before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.
6. Carefully remove the fuel supply -1- at the relevant connection unit (right connection unit here) and loosen the two disconnection points -2 and 3-. Also remove line (not shown here) in vehicles with auxiliary heating (auxiliary heater). Do the same at the left connection unit. Disconnect all connections on the connection unit.
7. Open the relevant cap with the key T10202 and lift up the connection unit (cap).
Removing left fuel pump
1. Pull off electric connectors -1 and 2- on the left connection unit. Then pull off the fuel lines -3 and 4- and remove the connection unit (filter unit).
2. Disconnect the sucking jet pump at the fuel pump. To do this, press on the left and right and pull off the connection.
3. Raise the right connection unit slightly and disconnect the fuel pump line at the Y-piece (on the right side).
4. Turn the pump approx. 90 degrees to the left until it disengages at the tank floor. Remove the pump from the tank.
Removing right fuel pump
1. Disconnect the electric connectors for the fuel pump and fuel level sensor. Then pull off the fuel lines on the pressure regulator and remove the connection unit.
2. Disconnect the sucking jet pump at the fuel pump. To do this, press on the left and right and pull off the connection.
3. Disconnect the hose for the right fuel pump at the Y-piece.
4. Turn the pump approx. 90 degrees to the left until it disengages at the tank floor. Remove the pump from the tank.
Installing fuel pump
Installing left fuel pump
1. Place the pump in the holder on the tank floor and turn it approx. 90 degrees to the right until it is seated securely.
2. Connect the fuel line from the pump to the Y-piece (right side of the tank).
3. Attach the sucking jet pump connection. This must engage audibly.
4. Replace both seals on the connection units.
5. Connect connection unit. Connect the electric connectors for the tank gauge and fuel pump. Then push on the fuel lines. The connectors must engage audibly.
6. Place the connection unit into the tank. When doing so, make sure that the plastic lug is pointing forwards.
Installing right fuel pump
1. Place the pump in the holder on the tank floor and turn it approx. 90 degrees to the right until it is seated securely.
2. Connect the fuel line from the right pump to the Y-piece.
3. Attach the sucking jet pump connection. This must engage audibly.
4. Replace connection unit seal.
5. Connect connection unit. Connect the electric connectors for the tank gauge and fuel pump. Then push on the fuel lines. The connectors must engage audibly.
6. 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 using the key T10202. Tightening torque 104 ft.lb.
2. Fit all connections (fuel lines, ventilation tubes and electric plugs).
3. Fit the lid. Then tighten the four fastening nuts. Tightening torque 7.5 ft.lb.Refit carpeted floor and fix with double-sided adhesive tape.
4. Tighten the seat-belt buckle fastening plates. Use three new fastening screws for this and tighten.
5. Fold rear seat down again.
6. Fill fuel tank (refuel).
Subsequent work
1. Fill fuel tank (refuel).