Fuel Pump, 4WD

Fuel Pump, 4WD

WARNING:
The work involved in removing the fuel pump requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:
^ Have a class BE fire extinguisher on hand. Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.
^ Absolutely No Smoking.
^ Ensure good ventilation. If there is approved ventilation for evacuating fuel fumes then this must be used.
^ Wear protective gloves. Prolonged exposure of the hands to fuel can cause irritation to the skin.
^ Wear protective goggles.

IMPORTANT: Be particularly observant regarding cleanliness when working on the fuel system. Loss of function may occur due to very small particles. Prevent dirt and grime from entering the fuel system by cleaning the connections and plugging pipes and lines during disassembly. Use 82 92 948 Plugs, A/C system assembly. Keep components free from contaminants during storage.

To remove
1. Remove Fuel tank, 4WD.
2. To prevent dirt entering the fuel system, clean the outside of the tank if necessary before removing the fuel pump.
3. Unplug the fuel pump connector (A) and the pressure sensor connector (B) and undo the quick coupling (C) at the carbon canister.





4. Remove the protective cover, turning anticlockwise. Lift the cover's flange so that the rivet passes the circlip.
5. Remove the fuel pump. Use tool 83 96 194 Fuel pump installer/remover to undo the fuel pump circlip.
6. Raise the fuel pump slightly, undo the quick coupling (A) for tank bleeding from the fuel pump and the quick coupling (B) for the ejector hose.





7. Carefully lift up the fuel pump and place it in a receptacle.

IMPORTANT: Take care not to damage the fuel level sensor.

8. Remove the seal (A).





To fit
1. Fit a new seal (A).
2. Fit the quick coupling (B) of the ejector hose. Lift up the bleeder hose and lower the fuel pump slightly. Secure the bleeder hose to the pump housing and fit the quick coupling (A) to the pump cover. Carefully lower the fuel pump into the tank.





3. Make sure the recesses (A) in the tank connection are in line with the corresponding lugs on the pump cover.





4. Ensure that the pump is in the right position according to the following:
^ guide lugs are in the right position in relation to the recesses (A).
^ the fuel pump connector (B) is in line with the rear long side of the tank.

5. Check that the seal is properly seating. Tighten the fuel pump fixing. Use 83 96 194 Fuel pump installer/remover.
6. Fit the protective cover, turning clockwise.
7. Plug in the fuel pump connector (A) and the pressure sensor connector (B) and fit the quick coupling (C) at the carbon canister.





8. Secure loose cables and lies to the recesses on the fuel tank.
9. Fit Fuel tank, 4WD.