Procedure

WARNING
As removing the fuel pump involves working on the car's fuel system, the following points must be observed:

^ Ensure that there is good ventilation! If an approved ventilation system for extracting fuel vapor is available, it should be used.

^ Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation of the skin.

^ Ensure that a class BE fire extinguisher is on hand! Be alert to the danger of sparks, e.g. on circuit breaking, short-circuiting etc.

^ Absolutely No Smoking!

^ Release the pressure in the fuel system by opening the nipple on the fuel rail Use a paper towel or cloth to soak up any escaping fuel. Retighten the nipple.

1 5D/CS: Lift out the parcel shelf, lift up the rear seat cushion and lower the backrest.

CD: Lift up the rear seat cushion and remove the backrest.





2 Remove the cover strip from behind the rear seat.

3 Fold back the rear section of the luggage-compartment floor. Remove the two screws and lift out the floor panel.

4 Remove the screws in the pump cover plate and move it out of the way.





5 Remove the plastic cover on top of the fuel pump and unplug the fuel pump connector.

6 Undo the catch for the delivery line and carefully pull the line away from the fuel pump.





7 Cut the fuel line at the slight curve located just before where the non-return valve connector nipple ends.





8 Fit tool 83 95 329 onto the fuel line. The end of the fuel line should protrude slightly.

9 Fit O-rings on the new non-return valve. Lubricate the new non-return valve with acid-free petroleum jelly and position it in the fuel line. Make sure it is turned the correct way as it cannot be turned when fitted and the hose is too stiff to twist.

10 Press in the non-return valve with the tool. Gradually move the special tool so that it is always close to the non-return valve connector nipple.

Important Take care not to bend the fuel line.

11 Fit the O-rings on the non-return valve and apply acid-free petroleum jelly to the O-rings on the nonreturn valve. Connect the delivery line to the fuel pump.

Make sure the catch locks the delivery line securely.





12 Plug in the fuel pump connector.

13 Start the engine and check for leaks. Fit the plastic cover on top of the fuel pump.





14 Refit the pump cover plate.

15 Fit the luggage compartment floor and replace the cover strip on the floor behind the rear seat.

16 5D/CS: Fold back the rear seat backrest and seat cushion and replace the parcel shelf.

CD: Refit the rear seat backrest and fold back the seat cushion.