Fuel Pump: Service and Repair

FUEL PUMP REPLACEMENT





4-Door Models:
^ Remove:
- Spare wheel cover.
- Trunk floor carpeting.





5-Door Models:
^ Remove:
- Left rear wheel-arch cover.
- Floor panel behind rear seat. (Fold down seatback to reach nuts and then draw panel forwards and upwards).





Remove:
^ Tank unit cover. Clean around tank unit and hose connections.
^ Hoses from tank unit. (Remove quick-release coupling by simultaneously pressure on hose and sliding sleeve upwards).

NOTE: Wear a mask to avoid inhaling fuel vapor.





Remove:
^ Hose clips around nut.
^ Nut to tank unit with tool P/N 9995448.
^ Lift up tank unit as far as electrical leads allow.
^ Seals.

NOTE: If tank nut is not replaced within about half a day, It must be changed or it will not fit and leakage will result.





Slack Off Pump
^ First detach lower pump fastener then upper fastener.
^ Disconnect electrical leads.
^ Slack off hose clip at pump.
^ Carefully remove pump from hose.
^ Change pump.

Fit:
^ Pump electrical wiring.
^ Pump to hose and tighten hose clip.
^ Attach upper fastener first.
^ Press in lower fastener.





Fit Tank Unit
^ Fit new seal to tank opening.
^ Grease tank unit contact surface with a thin layer of petroleum Jelly (glycerol).
^ Lower tank unit into tank, taking care not to damage pump fixings against tank wash-plates. Check that seal is not drawn into tank.





Locate Tank Unit
^ Locate position marks against tank plastic joints.
^ Enter nut and tighten with tool P/N 9995448, taking care not to damage nipples.
^ Lock with hose clip.





Fit:
^ Hoses. Check that hoses cannot slip off pipes on tank unit.
^ Tank unit cover.





Carry Out Function Check
^ Check pump and measurement functions.





4-Door Models:
^ Fit:
- Spare wheel cover.
- Trunk floor carpeting.





5-Door Models:
^ Fit:
- Left rear wheel-arch cover.
- Floor panel behind rear seat.