Fuel Pump Unit, Replacing
Fuel pump unit, replacing
Special tools:
981 2270 PUMP TROLLEY 981 2270 Pump Trolley
981 2273 PUMP 981 2273 Pump
981 2282 Tank 981 2282 Tank
998 5972 JACK 998 5972 Jack
999 5484 Adapter 999 5484 Adapter
999 5485 KEY 999 5485 Key
999 5561 COUNTERHOLD 999 5561 Counterhold
999 5666 Wrench 999 5666 Wrench
999 5673 Counterhold 999 5673 Counterhold
Safety
First see Safety regulations for handling fuel Safety Regulations For Handling Fuel.
Preparation
Draining the fuel tank
To drain the fuel tank, see Draining the fuel tank AWD and 2WD/ORVR Draining the Fuel Tank (IE00)
If you have drained the fuel tank according to the "non working fuel pump" method continue according to Fitting the fuel pump units and then Fitting the rear suspension assembly.
Draining the fuel system
To drain the fuel system, see Draining fuel injection system .
Removing the luggage compartment floor
Remove the front and rear luggage compartment floor.
Unplugging the connectors
Undo the ABS sensor and fuel level sensor connectors.
Remove the connectors' holder and the front cover.
Feed the leads through the hole.
Detaching the filler pipe
Remove the lock ring from the rubber gaiter.
Press the rubber gaiter and filler pipe into the wheel housing.
Disconnecting the rear wheels
Remove:
- rear wheels
- right-hand wheel arch liner and mud flap.
Disconnecting the fuel tank EVAP lines
Remove the protective cover from the fuel lines.
Removing the protective covers in front of fuel tank
Remove:
- protective covers at front edge of fuel tank (three plastic nuts on each cover)
- all pipes from the plastic clips on the fuel tank.
Removing the exhaust pipe
Remove the rear exhaust pipe and silencers.
Detaching the longitudinal stay mountings
Detach the longitudinal stay mountings from the body.
Position an engine lift gently against the longitudinal stay mounting.
Remove:
- bolts for jack attachment and longitudinal stay mounting in body, both sides
- engine lift.
Undo:
- three-way branching on left-hand jack attachment.
- front brake pipe from the 4 clips under the car.
Removing the hand brake cable
Remove the hand brake cable from the jack attachment by drilling out the pop rivet (B).
Tie the jack attachment to the longitudinal stay brackets (A). Use a cable tie.
Removing the propeller shaft
Mark the propeller shaft in relation to the driver.
Note! Note the bolt length and location on the CV joint. See the table below (standard bolts for front and rear CV joints and balancing bolts for rear joint).
Remove the propeller shaft bolts. Use holding tool 999 5561 COUNTERHOLD 999 5561 Counterhold. Move the shaft to one side.
Standard bolts for front and rear CV joints and balancer bolt for rear CV joint
Note! Before removing the propeller shaft from the companion flange: Carefully mark the position of the propeller shaft in relation to the companion flange. Check also whether balancer bolts are fitted. Where applicable, note the position and length of the balancer bolts.
Note! If the previous propeller shaft is refitted without replacement of the rear joint or removal or replacement of the companion flange on the differential, perform the following: fit the propeller shaft using the markings made upon removal (see previous section). Use new bolts of the same length as those removed. If the propeller shaft is to be changed, the new shaft must be fitted with new bolts of standard length.
Lowering the torque tube
Position the jack 998 5972 JACK 998 5972 Jack against the torque tube.
Remove the bolt and lower the torque tube with the engine lift.
Removing the rear suspension assembly
Positioning the lifting table
Place the lifting table with fixture under the tank and link arms. See illustration.
Caution! Secure the front part of the differential to the lifting table. This prevents the rear suspension from tipping backward when lowered.
Removing the tank strap bolts
Remove the tank strap bolts from both sides.
Removing the rear axle member bolts.
Remove the bolts securing the rear axle member to the body on both sides.
Lowering the rear suspension with fuel tank
Carefully lower the rear suspension and fuel tank about 30 cm.
Check that the fuel filler pipe is clear of the wheel arch lining.
Note! Check also that the fuel line between the fuel level sensor and the ejector pump does not foul the body during lowering.
Note! Check that the brake pipes are clear.
Removing the fuel lines.
Caution! Note the position of the fuel lines on the tank so that they are given corresponding positions on the new tank.
Unhook the fuel lines from their mountings.
Caution! Plug the disconnected fuel line fittings with part number 1203219-9 (door button 200/700/900) to prevent fuel spills.
Remove:
- the fuel lines from the fuel pump and ejector pump, use special tool 999 5666 Wrench 999 5666 Wrench
- fuel line attachments between the fuel pump and fuel filter.
Note! Do not remove the fuel line between the fuel pump and the ejector pump.
Removing the fuel lines from the clips
Remove the return line from the ejector pump (left-hand side).
Remove the pump units
Remove:
- pump unit on left-hand side
- pump unit on right-hand side. Use special tool 999 5485 KEY 999 5485 Key.
Fitting the fuel pump units
Fitting the fuel pump units
Install:
- new washers
- left-hand pump unit
- right-hand pump unit
Grease all contact surfaces of the pump units' retaining nuts with Vaseline.
Note! Do not apply Vaseline to the nut threads.
Tighten the nuts with 40 Nm . Use special tool 999 5673 Counterhold 999 5673 Counterhold as a counterhold. The tool's indicator tip must be between the markings on the fuel tank in order for the placement of the pump units to be correct.
Note! Make sure the pump units are correctly positioned so that the fuel gauge shows the correct value.
Fitting the rear suspension assembly
Fitting the fuel lines
Position and secure the fuel lines to their mountings in the same order as they were removed.
Install:
- Fuel line attachments between the fuel pump and fuel filter.
- fuel lines from the fuel pump and ejector pump.
Fitting the fuel lines to the clips
Fit the return line from the ejector pump (left-hand side).
Fitting the hand brake cable
Raise the rear suspension about 10 cm.
Remove the cable tie (A).
Fit the hand brake cable with clips, use a pop rivet (- 4 mm) (B).
Raising the rear suspension with fuel tank
Raise the rear suspension and fuel tank.
Make sure the fuel filler pipe does not foul the wing liner. Make sure the fuel line is clear of the body and that the fuel level sensor line does not get caught in the fuel strap brackets.
Lift up the tank fitting lines and fuel pump lines through the body (hatch).
Caution! Secure the front part of the differential to the lifting table. This prevents the rear suspension from tipping backward when lowered.
Note! Check also that the fuel line between the fuel level sensor and the ejector pump does not foul on the body when the rear suspension is lifted.
Adjust and secure the filler pipe's crash protection bracket.
Fitting the retaining bolts for the rear axle member.
Apply a couple of drops of thread lock, part number 1161351-0, to each bolt.
Fit all the retaining bolts for the rear axle member.
Note! Before fitting the rear axle to the body, measure the distance between the rear axle member guide - 16.5 mm holes (A) outside the rear retaining bolts, and the -16 mm holes furthest to the rear on the side members. The distance between the holes should be 595 mm ± 2 mm.
Tighten the outer bolts to 80 Nm and the centre bolts to 50 Nm .
Tightening the tank strap attachments
Tighten the tank strap attachments on both sides.
Remove the lifting table.
Fitting the fuel tank EVAP lines
Install:
- brake pipe in the 4 clips
- fuel and EVAP lines
- lines to protective cover
- protective cover, use new nuts and washers
- protective covers in front of fuel tank.
Fitting the propeller shaft and driver
Fit the propeller shaft to the driver.
Note! Fit the propeller shaft as marked earlier. Refit the bolts in their original positions.
Check the contact surfaces of the viscous coupling and propeller shaft drivers are clean.
Tighten opposite bolts to 8 Nm . Then tighten opposite bolts to 30 Nm . Use holder 999 5561 COUNTERHOLD 999 5561 Counterhold
Start by tightening the same bolt both times.
Fitting the longitudinal stay mountings and jack attachments
Fit the front longitudinal stay mountings and the jack attachments to the body.
Press up the link arms to their normal position.
Connect the left-hand three-way branching to the left-hand jack attachment.
Fit the longitudinal stay brackets and the jack attachments using new bolts.
Tighten the three bolts for the longitudinal stay bracket to 65 Nm + 60° .
Tighten the bolt through the jack attachment to 105 Nm + 90° .
Fitting the exhaust pipe
Install:
- rear exhaust pipe
- silencers.
Note! Check that there is clearance to the heat shields.
Fitting the filler pipe
Fit the fuel filler pipe to the body with the rubber gaiter and lock ring.
Fitting the hatches and connections to the tank fitting
Install:
- front and rear hatch in the body and the connector holder. Make sure the rubber seal around the wiring is properly fitted when the rear hatch is fitted.
- connectors to the tank fitting, fuel pump and ABS system.
Positioning the luggage compartment floor mountings
Position:
- mounting at front edge of luggage compartment floor. Fit the screws along the rear edge.
- hatch with the rear floor hatch.
Tighten the screws.
Fitting the rear wheels
Install:
- wheel arch liner and mud flap on rear edge on right-hand side.
- rear wheels.
Refill the fuel tank.
Test drive and perform functional checks.