Fuel Pump: Service and Repair

Special tools
999 5533
999 5485

Caution: FIRE RISK Maximum care must be taken to avoid sparking during any fuel system work.

Disconnect battery

Drainage of fuel system





- Drain fuel system as described in Drainage of fuel system, refer to Powertrain Management.

Preparations
5-door models:





- Raise front floor cover and fold back carpet.

4-door models:
- Tilt rear seat forward.

Remove





- luggage compartment carpet and right-hand wheel housing panel. It is sufficient to fold back corner of panel on certain variants with soft panel.
- cover over 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.

Disconnection of connector

Fuel Pump Connectors:

- 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 999 5533. Slide outer sleeve of coupling upward without squeezing sleeve.

Removal of pump

Fuel Pump Nut:

- Remove pump unit nut.
Use tool 999 5485.

Fuel Pump Removal:

- Lift out pump unit.
- Remove rubber seal.

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

Caution: 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 Vaseline.
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.

Installation of hoses

Fuel Pump Nut Installation:

Install fuel pump unit nut and tighten to 40 Nm (30 ft., lbs.) using tool 999 5485.
Grease delivery and return hoses lightly with Vaseline.
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 O-rings are not damaged.

Note! Ensure that leads are correctly positioned.

Connect leads.

Install

Fuel Tank Access Covers:

- panel on right-hand side
- cover over pump unit nut
- luggage compartment mat

Raise right-hand rear seat
Reconnect battery
Re-enter radio code