Fuel Pump, Replacement

Fuel pump, replacement

Special tools:
999 5533 Holder 999 5533 Holder
999 5485 KEY 999 5485 Key

Caution! RISK OF FIRE The greatest possible care must be taken to avoid spark buildup when working with the fuel system.

Safety
See first Safety regulations for handling fuel Safety Regulations For Handling Fuel.

Emptying the fuel system




- Empty the fuel system as per Draining fuel injection system Draining Fuel Injection System.

Preparations





5 door car
- Open the front floor hatch and fold back the mat.

4 door car
- Fold the right-hand rear seat forward.
Remove:
- The cargo compartment mat and right-hand wheel house panel. On certain variants with soft panels, it is enough to fold up the corner of the panel.
- Cover over the fuel pump nuts.

Note! To make any repairs to the fuel level sensor for 5 door cars, fold the rear seat forward, remove the screws (4) of the front floor hatch and pull the hatch rearwards.

Disconnecting connectors




- Separate the connector to the fuel pump.
Check the color markings on the hoses and pump.

Note! The feed line is marked with yellow tape, corresponding to the color marking on the pump.

Disconnecting hoses




- Carefully remove the quick couplings of the feed and return lines.
Use tool 999 5666 Wrench 999 5666 Wrench. Move the outer sleeve of the coupling upward. Avoid pinching the sleeve.

Removing the fuel pump fitting




- Remove the nut of the fuel pump fitting.
Use wrench 999 5485 KEY 999 5485 Key.




- Remove the pump unit.
- Remove the rubber seal.

Caution! Lift straight up. Do not use pliers or sharp objects on the pipe connections. There is a risk of fuel leakage.

Caution! Refit the nut on the tank casing. Otherwise, the neck will swell and it will be difficult to fit the nut later.

Mounting the fuel pump fitting




Use a new dry gasket, no. 3531426-9. Make sure it is fitted correctly. Lubricate the top plane surface of the inside the narrow outer edge with a thick layer of Vaseline.
Lubricate the top edge of the rubber seal so that it does not rub against the nut.
The fuel pump fitting should be fitted with the connection for the heater to the right, see arrow.

Note! If the fuel pump fitting is incorrectly mounted, there is a risk of breakdown.

- Mount the fuel pump fitting.

Fitting the hoses




Fit the nut on the fuel pump fitting and tighten to 40 Nm with tool 999 5485 KEY 999 5485 Key.
Lightly grease the feed and return connections with Vaseline.
Fit the feed and return lines to the fuel pump fitting. The feed line is marked with yellow, corresponding to the marking on the pump flange.
Fit the couplings straight and press down to the pump's plane surface. Be careful not to damage any O-rings.

Note! Ensure that the lines are correctly positioned.

Connect the cable harness.
Fit the panels and mats.