Fuel Pump: Service and Repair

Fuel Rail Service Port:

Draining Fuel System
- Drain fuel system.





Preparation
5-door models:
- Remove all floor hatches and fold back carpet.
- Remove the cover over the fuel pump (FP) unit.

4-door models:
- Fold right rear seat forwards
- Remove luggage compartment mat
- Fold back corner of wheel arch panel by shock absorber mounting.
- Remove the cover over the fuel pump unit.

NOTE: If carrying out work on fuel level sensor in a 5-door model, fold the rear seat forward, remove the front floor cover screws (four) and pull cover backward.





Disconnecting Of Connector
- Disconnect fuel pump connector.
- Check color markings on hoses and pump.

NOTE: Delivery hose is marked with yellow tape, corresponding to color code on pump.





Disconnecting Hoses
- Carefully disconnect quick-release connectors on delivery and return hoses.
- Use tool 999 5533. Slide outer sleeve of connector upward. Avoid squeezing sleeve.

Fuel Pump Nut:

Removing Fuel Pump Unit
- Remove fuel pump unit nut. Use wrench 999 5485.

Fuel Pump Removal:

- Lift out fuel pump unit.
- Remove rubber seal.

NOTE: Lift unit straight up. Do not grip pipe connections with pliers or other sharp tool as damage to connections may result in fuel leakage.

CAUTION: Reinstall fuel pump unit nut, otherwise the collar may swell, causing difficulty in reinstalling nut when reinstalling unit.





Installing Fuel Pump Unit
- Use new, dry seal, P/N 3531426-9. Ensure that seal is correctly seated. Lubricate with a thin layer of petroleum jelly on the upper flat surfaces on the inside and the outer narrow edge.
- Lubricate the upper edge of the rubber seal so that it does not stick to the nut.
- Install fuel pump unit with heater connection facing towards right of car, see arrow.

CAUTION: Engine may stall if the fuel pump unit is installed incorrectly.

- Install fuel pump unit.

Fuel Pump Nut Installation:

Installing Hoses
- Install fuel pump unit nut and tighten to 40 Nm with tool 999 5485.
- Grease delivery and return hoses lightly with petroleum jelly.
- Reconnect delivery and return hoses to fuel pump unit. Delivery hose is marked with yellow tape, corresponding to color coding on pump flange.
- Reconnect quick-release connectors straight. Press down to flat surface of fuel pump. Ensure that 0-rings are not damaged.

NOTE: Ensure that cables are correctly positioned.

- Connect connector to fuel pump.
- Install panels and carpets.