Fuel Pump: Service and Repair

Fuel pump assembly, removing/installing

Removing

WARNING: Fire hazard. Do not have anything in area that can ignite fuel.

- switch ignition OFF
- disconnect battery ground strap

CAUTION:
- Wait at least 20 seconds after switching off ignition before disconnecting battery. This will allow the platinum hot-wire in the Mass Air Flow (MAF) Sensor to burn itself clean.
- Always switch off ignition when disconnecting or reconnecting battery or any part of Motronic system to prevent damage to Motronic engine control module (ECM).
- Always obtain radio security code before disconnecting battery ground strap.

- remove cover plate in luggage compartment floor
- disconnect harness connector and fuel lines from flange




- unscrew flange nut using special tool 3217
- withdraw flange and O-ring from opening on fuel tank
- loosen and remove supply unit from bayonet lock by turning to the left


Installing

Reinstall all components in reverse order, noting the following:

CAUTION: Ensure that the sender is not bent when reinstalling.




- fuel pump assembly is correctly installed when sender float angle (from direction of travel A) is 5°
- coat flange sealing ring with fuel before installing





- align mark on flange with mark on fuel tank, as shown