Fuel Pump: Service and Repair

WM 206619 Removing and installing fuel pump

Tools





Technical values





Preliminary work

WARNING

Toxic substances

- Danger of poisoning or suffocation

-> Ventilate the work area well.
-> Never ingest or inhale.
-> Read specific information on the Hazard Sheet.
-> Wear personal protective gear.

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 fuel filter is integrated in the right connection unit, while the pressure regulator is in the fuel pump (delivery unit).

1. Drain the tank if necessary. -> 2010EN Draining and filling the fuel tank (draining and filling in fuel) Procedures
1.1. The fuel tank should be drained before opening the flange under the rear seat. If the displayed fuel level is less than the reserve, there is no need to drain the tank.
1. Remove (pull off) the right cover -3- in the bodyshell opening.
1.1. Loosen and fold up the right rear seat. -> 724819 Removing and installing rear seat - section on "Removing" 724819 Removing and installing rear seat
1.2. Pull off the right cover under the rear seat -3-. To do this, pull away the carpeted floor.





Cover and bodyshell openings

Removing fuel pump

WARNING

Toxic substances

- Danger of poisoning or suffocation

-> Ventilate the work area well.
-> Never ingest or inhale.
-> Read specific information on the Hazard Sheet.
-> Wear personal protective gear.

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 fuel pump is supplied as a spare part complete with a sucking jet pump and line assembly (see Spare Parts Catalogue).





Piping diagram in approximate installation position (components removed on workshop floor)





1. Disconnect the right fuel-tank flange under the rear seat.
1.1. Disconnect connections at the right fuel-tank flange. -1, 2 and 3- (3 only for auxiliary heater)





Right flange

2. Remove flange using a wrench T10202. => Special tool on flange ring





Special tool on flange ring

3. Lift up the flange and disconnect all connections. Mark the plug connections with adhesive tape while doing this (this makes installation easier).
4. The fuel pump sits in the fuel tank at the front right in direction of travel (in the front corner). => Installation position of fuel pump





Installation position of fuel pump

5. Unclip fuel-level sensor and pull it out of the mounting. - 1-





Sucking jet pump holder 2 and fuel-level sensor 1

6. Remove fuel-level sensor and disconnect cable. -1 and 2-





Cable connection for fuel-level sensor

7. Unclip sucking jet pump holder and pull it out of the holder. -1-





Sucking jet pump holder

8. Mark fuel pump lines (to avoid confusion) and disconnect them. -7 and 12-
9. With one hand -1- and wearing a thin, non-slip glove, take hold of the fuel pump -2- through the opening in the tank and turn it to the left to remove it from the floor lock. => Fuel pump lock on fuel tank floor Take note of the installation position of the pump (position of hoses).





Reaching into the tank





Fuel pump lock on fuel tank floor





10. Release fuel pump. First guide lines in the fuel tank with sucking jet pump out of the opening.
11. Remove the fuel pump. => Fuel pump





Fuel pump

Installing fuel pump

1. Installation is carried out in reverse order. During installation, make sure that the lines you marked during removal are routed and fitted again correctly. Check that all locking mechanisms are seated securely by pulling on them.
2. Replace seals when refitting the flanges. => Seals on flanges





Seals on flanges

3. Fit the flanges using a wrench T10202. => Special tool on flange ring => Tightening torque: 110 Nm (81.5 ftlb.)





Special tool on flange ring

Subsequent work

1. Fit cover -3- in the bodyshell opening.
1.1. Pull on cover under the rear seat -3-. Observe arrow marking between cover and bodyshell. Fit the carpet.





Cover and bodyshell openings

1.2. Fit the right rear seat.