Fuel Pump: Service and Repair
FUEL PUMP REPLACEMENTFIRERISK: Maximum care must be taken to avoid sparking during any tuel system work.
Fuel Rail Service Port:
Release of Fuel System Pressure
^ Drain fuel system pressure. See: SYSTEM DIAGNOSIS / DRAINAGE OF FUEL SYSTEM.
Preparations
5-door models:
^ Tilt forward right-hand rear seat.
4-door models:
^ Raise front floor cover and fold back carpet.
^ Remove:
- Luggage compartment carpet and right-hand wheel housing panel. It is sufficient to fold back a corner of the panel on certain variants with a soft panel.
- Cover above fuel pump nut.
NOTE: If carrying out work on fuel level transmitter in a 5-door model, fold the rear seat forward, remove the front floor cover screws (four) and pull cover backward.
Fuel Pump Connectors:
Disconnection of Connector
^ Undo fuel pump connector.
^ Check color markings on hoses and pump.
NOTE: Delivery hose is marked with yellow tape, corresponding to color code on pump.
Disconnection of Hoses
^ Carefully disconnect quick-release couplings on delivery and return hoses.
^ Use tool P/N 9995533. Slide outer sleeve of coupling upward without squeezing sleeve.
Fuel Pump Nut:
Removal of Pump Unit
^ Remove pump unit nut. (Use tool P/N 9995485).
Fuel Pump Removal:
^ Lift out pump unit.
^ Remove rubber seal.
NOTE: Lift unit straight upwards. Do not grip pipe connections with pliers or other sharp tool as damage to connections may result in fuel leakage.
NOTE: Refit pump unit nut, otherwise connection branch on tank may swell, causing difficulty in refitting nut when reinstalling unit.
Installation of Pump Unit
^ Use new, dry seal, P/N 3531426-9. Ensure that seal is correctly seated. Lubricate flat, upper surface of inner face and narrow, outer edge of seal with thin coating of petroleum jelly.
^ Grease upper edge of seal to prevent it being gripped by nut.
^ Install pump unit with heater connection facing towards right of car as illustrated.
NOTE: Engine may stop if fuel pump unit is installed incorrectly.
Fuel Pump Nut Installation:
Installation of Hoses
^ Install fuel pump unit nut and tighten to 40 Nm (30 ft lb) using tool P/N 9995485.
^ Grease delivery and return hoses lightly with petroleum jelly.
^ Reconnect delivery and return hoses to pump unit.
^ Delivery hose is marked with yellow tape, corresponding to color coding on pump flange.
^ Reconnect quick-release couplings, ensuring that couplings are straight. Press against flat pump face, ensuring that 0-rings are not damaged.
NOTE: Ensure that leads are correctly positioned.
^ Connect leads.
^ Install panels and carpets.