FWD

Removing And Installing Fuel Pump


CAUTION: To remove the Fuel Pump (FP), the fuel tank may only be filled to a maximum of 3/4. Empty fuel tank if necessary.


Recommended special tools and equipment







- 3087 wrench for tank sensor







- VAS5190 fuel siphoning device

Empty fuel tank
Observe safety precautions.
Observe rules for cleanliness.


CAUTION: Observe safety precautions when disconnecting the battery.


- Disconnect battery Ground (GND) strap with the ignition switched off.


CAUTION: Secure Ground (GND) wire of VAS5190 to a blank portion of the chassis.







- Pull cone piece -2- from shaft piece -1- of VAS 5190.
- Using insulating tape, apply a mark -arrow- on hose at length a = 1465 mm from end of suction hose.
- Remove fuel filler cap from fuel filler tube.







- Screw shaft piece -1- of VAS 5190 fuel siphoning device on to fuel filler tube of fuel tank.
- Now slide suction hose as far into fuel tank until the mark applied earlier -arrow- stands on shaft piece.

NOTE:
- If using a siphoning device without shaft piece, proceed principally in the same manner.







- In this case, apply a mark -arrow- on hose at length a = 1400 mm from end of suction hose using insulating tape. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube.
- If the hose can only be inserted with difficulty, smear it thinly with engine oil. Never use lubricants containing silicon.

- Drain fuel tank through fuel filler tube.
- Carefully remove siphoning hose.

Removing

Sedan:
- Remove luggage compartment lining.
- Push forward the right backrest of rear seat, if necessary.

Avant:
- Remove left 1/3 backrest.
- Remove left side trim in luggage compartment and dirt tray.

All:







- Remove cover for connector flange (arrows).







- Release and disconnect harness connector -1-.
- Disengage electrical harness connector -2- and lay it aside.


CAUTION:
- Work on the fuel system must only be performed when engine is cold.
- Fuel system is under pressure. Before opening system, place rags around the connection area. Then release pressure by carefully loosening connection.







- Mark and disconnect fuel supply line -1- and fuel return line -3- (press release tab).
- Disconnect ventilation line -2- (press release button).







- Use e.g. 3087 wrench to remove locking ring.
- Lift out fuel pump with sealing ring slightly from opening of fuel tank
- If Fuel Pump (FP) is still inserted in fuel tank, slide connector flange slightly to the side.







- Grasp through the gap between connector flange and installation opening in fuel tank and release suction jet pump -1-.


NOTE: Fuel tank is depicted as cut-out section.







- Pull suction jet pump -1- upward with suction jet pipe -2- still connected.
- Disconnect suction jet pipe from suction jet pump (press release button).
- Remove suction jet pump.
- Remove Fuel Pump (FP).

Installing
Installation is the reverse of removal, noting the following:







- Connect suction jet pipe -2- to connection for suction jet pump -1-.
- Insert Fuel Pump (FP) into fuel tank.







- Clip in suction jet pump -1- on Fuel Pump (FP). To do so, insert hand into gap between connector flange and installation opening of fuel tank.
- Suction jet pump must engage audibly

- Insert new, dry seal for connector flange into opening of fuel tank.







- Note installation position of Fuel Pump (FP):
- The tab -2- on connector flange must lie between tabs -1- and -3- on fuel tank.


NOTE: Arrow points in direction of travel.







- Tighten locking ring.







- Install fuel supply line -1- and fuel return line -3- according to the marking.
- Install ventilation line -2-.
- Connect electrical harness connectors.
- Observe safety precautions after connecting the battery.

Tightening torques

Component Nm
Locking ring for Fuel Pump (FP) 145
Battery terminal to battery post 6

Final procedures
After re-connecting the voltage supply, the following work steps must be performed in the mentioned sequence:
1 - Vent fuel system.
2 - Check DTC memory, see "Mode 3: Check DTC memory".
3 - If necessary, erase DTC memory, see "Mode 4: Reset/erase diagnostic data".
4 - Generate readiness code.

- End diagnosis and switch ignition off.