Fuel Pump: Service and Repair

WM 206619 Removing and installing fuel pump - Turbo

Technical values





Preliminary work

1. Place protective covers on the vehicle to avoid damaging the vehicle.
2. Disconnect the battery.
-> 2706IN Work instructions after disconnecting the battery 2706IN00 Work instructions after disconnecting the battery.
3. Remove luggage compartment cover.
-> 700519 Removing and installing trim panel for front luggage compartment - section on "Removing" .
4. Remove cover for access to the fuel level sensor.
4.1. Screw off four M6 nuts -2- and remove the cover.
4.2. Check seal and replace it if necessary.





Cover for access to fuel level sensor

WARNING

Highly inflammable or explosive materials

- Danger of fire or explosion

-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.

5. Display a warning sign in a clearly visible position in the work area or attach it to the vehicle.





Example of warning sign

6. Remove fuel level sensor.
-> 200019 Removing and installing fuel level sensor - Turbo - section on "Removing"
7. Drain the fuel tank until the fuel level is lower than the fuel pump.
-> 200317 Draining and filling fuel - section on "Draining".

Removing fuel pump

WARNING

Highly inflammable or explosive materials

- Danger of fire or explosion

-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.

Information

The installation position specifications (right/left) refer to the direction of travel.

1. Expose the fuel pump.





Connections for right fuel pump

1.1. Pull off flexible breather hose for the filler neck (blue) -1- and plug-in coupling for the fuel line -2- at the right.
1.2. Disconnect the plug-in coupling for the fuel line on the fuel pump -1- at the left and pull off the line.





Connection for left fuel pump

2. Remove the fuel pump.





Connection for sucking jet pumps

2.1. Turn the fuel pump anti-clockwise (bayonet lock) and tilt slightly forward in direction of travel.
Observe installation position of fuel pump!
2.2. Release and pull off connection for the left and right sucking jet pump at the fuel pump -2-.
2.3. Carefully lift the fuel pump up out of the fuel tank.

Installing fuel pump

WARNING

Highly inflammable or explosive materials

- Danger of fire or explosion

-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.

Information

The installation position specifications (right/left) refer to the direction of travel.

1. Install fuel pump.
1.1. Guide the fuel pump into the fuel tank and set it down on the floor of the tank in order to connect the sucking jet pumps.
1.2. Fit and engage connection for the left and right sucking jet pump at the fuel pump -2-.





Connection for sucking jet pumps

1.3. Insert the fuel pump into the mounting (bayonet lock) and turn it clockwise as far as it will go.
Observe installation position of fuel pump!
1.4. Connect plug-in coupling for the fuel line (blue) -1- to the fuel pump at the left.





Connection for left fuel pump

The plug-in coupling must lock with an audible click.
2. Connect flexible breather hose for the filler neck (blue) -1- and plug-in coupling for the fuel line -2- at the right.





Connections for right fuel pump

The plug-in coupling must lock with an audible click.

Subsequent work

1. Install fuel level sensor.
-> 200019 Removing and installing fuel level sensor - Turbo - section on "Installing"
2. Fill fuel that was removed back into the fuel tank.
-> 200317 Draining and filling fuel - section on "Filling".
3. Install cover for access to the fuel level sensor. Fit and tighten four M6 nuts -2-.





Cover for access to fuel level sensor

=> Tightening torque: 10 Nm (7.5 ftlb.).
4. Install luggage compartment cover.
-> 700519 Removing and installing trim panel for front luggage compartment - section on "Installing" .
5. Connect the battery.
-> 2706IN Work instructions after disconnecting the battery 2706IN00 Work instructions after disconnecting the battery.
6. Carry out a function test and check the system for leaks.
7. Remove protective covers from the vehicle.