Removing and Installing Fuel Pump (In-Tank Fuel Pump)
Removing And Installing Fuel Pump (In-Tank Fuel Pump) On DFI Engines
Tools
Technical Values
Preliminary work
DANGER:
Danger of poisoning from fuels.
- Gasoline is toxic.
- Inhaling vapours can cause irritation of the mucous membranes and eyes.
- It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.
- Only work on the fuel system in well-ventilated rooms.
- Wear protective gloves that are fuel-resistant.
- Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
- Ensure that there is adequate ventilation and extract all fuel vapours.
- Before opening the fuel lines or fuel hoses, relieve the fuel pressure.
- Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
- Pay attention to cleanliness when working on the fuel system.
DANGER:
Danger of fire from fuel.
- Keep clear of ignition sources.
- Do not smoke.
- Disconnect battery.
- Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
- Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. Allow engine to cool down.
- Secure the vehicle, e.g. with a warning sign.
- Change any clothing soaked with fuel immediately.
- In case of fire, use CO2 or dry powder fire extinguishers.
1. Empty the fuel tank.
Relieve the fuel pressure
1. Switch off the ignition.
2. Pull out fuses 13 and 14.
3. Start the engine and wait until the engine starts up automatically.
1. Loosen rear seat and fold it up. Secure to the headrest using a piece of wire if necessary.
5. Loosen the reinforcement plate for the seat-belt buckle. To do this, loosen the three fastening screws and twist the plate with the seat-belt buckle to the side. Do not use the same fastening screws again.
6. Loosen the cap (figure shows both) -arrows-. To do this, remove the carpeted floor. Then loosen the four fastening nuts and remove the cap.
7. Disconnect all connections on the relevant connection unit. Pull off cable plug.
8. Open each cap using special key T10202 and lift up the connection unit (cap).
Information
Assembly overview of components in the fuel tank
INFORMATION:
- The fuel pumps have different hose connections and must not be confused.
- The connections should be marked for identification when removing.
- In order that the connections do not fall in the fuel tank, they should be secured using tie-wraps.
The overviews provided below are intended as a guide for the fuel pump connections:
Removing fuel pump
Removing left fuel pump
INFORMATION: Both connection units must be removed in order to remove the left fuel pump.
1. Disconnect the electric connectors and plug connections for the fuel lines on the left connection unit -2-. Then remove the connection unit (filter unit).
2. Disconnect the sucking jet pump at the fuel pump. To do this, press on the left and right and pull off the connection.
3. Raise the right connection unit slightly and disconnect the fuel pump line at the Y-piece (on the right side).
4. Turn the left pump approx. 90 degrees to the left until it disengages at the tank floor. Remove the fuel pump from the tank.
Removing right fuel pump
1. Disconnect the electric connectors and plug connections for the fuel lines on the right connection unit -1-. Then remove the connection unit (pressure regulator).
2. Disconnect the sucking jet pump at the fuel pump. To do this, press on the left and right and pull off the connection.
3. Disconnect the hose for the right fuel pump at the Y-piece.
4. Turn the pump approx. 90 degrees to the left until it disengages at the tank floor. Remove the fuel pump from the tank.
Installing fuel pump
Installing left fuel pump
1. Place the new pump in the bracket on the tank floor and turn it approx. 90 degrees to the right until it is seated securely.
2. Connect the fuel line from the pump to the Y-piece (right side of the tank).
3. Connect the sucking jet pump connection. This must lock with an audible click.
4. Replace both seals on the connection units.
5. Connect the connection unit.
6. Fit the connection unit into the tank. When doing so, make sure that the plastic lug is pointing forward.
Installing right fuel pump
1. Place the new pump in the bracket on the tank floor and turn it approx. 90 degrees to the right until it is seated securely.
2. Connect the fuel line from the right pump to the Y-piece.
3. Connect the sucking jet pump connection. This must lock with an audible click.
4. Replace the seal on the connection unit.
5. Connect connection unit. Connect the electric connectors for the tank gauge and fuel pump. Then push on the fuel lines. The connectors must engage audibly.
6. Place the connection unit into the tank. When doing so, make sure that the plastic lug is pointing forward.
Subsequent work
1. Close the fuel tank. To do this, fit the sheetmetal ring and tighten using special key T10202. - Tightening torque: 140 Nm (104 ftlb.)
2. Fit all connections (fuel lines, ventilation tubes and electric connectors).
3. Fit the caps. Then tighten the fastening nuts on each cap. - Tightening torque: 10 Nm (7.5 ftlb.) Refit carpeted floor and fix in place with double-sided adhesive tape.
4. Tighten the mounting plates for the seat-belt buckles. Always use new fastening screws.
5. Fold rear seat down again.