206619 Removing and installing fuel pump

WM 206619 Removing and installing fuel pump

Tools





Technical values





Preliminary work

1. Disconnect the battery. -> 2X00IN Work instructions after disconnecting the battery 2X00IN Work instructions after disconnecting the battery
2. Open the filler flap.
3. Drain the fuel tank if necessary. -> 200317 Draining and filling fuel - section on "Draining" Procedures
4. Remove rear seat. -> 724819 Removing and installing rear seat - section on "Removing" 724819 Removing and installing 1/3-split folding rear seat 724819 Removing and installing 2/3-split folding rear seat
5. Remove the left and right cap -arrows-. To do this, remove the carpeted floor. Then loosen the four fastening nuts and remove the cap.





Fastening nuts on caps





Left and right connection units

6. Disconnect all connections on the right connection unit. Disconnect electric plug connections.





Fuel supply and connection points at right connection unit

7. Disconnect electric plug connection on the left connection unit.





Connector for left connection unit

8. Open the left and right lock using wrench T10202 and lift up the connection unit. => Special tool on cap





Special tool on cap

Information

Component information





Connection overview, lines for fuel filter





Removing fuel pump





Left and right connection unit





1. Disconnect all connections apart from the fuel line -3- on the underside of the right connection unit.
2. The fuel line -3- cannot be disconnected from the pressure regulator (right connection unit).





Fuel line on pressure regulator

3. Disconnect the fuel line -3- from the left connection unit.





Fuel line on left connection unit

4. Attach a piece of wire or similar item to the fuel line in order to pull the line back through the fuel tank during installation.
5. Remove the right connection unit (with pressure regulator) completely.
6. Disconnect the sucking jet pump at the fuel pump. To do this, press on the left and right -arrows- and pull off the connections -1 and 2-.





Sucking jet pump connections at the fuel pump

7. Release connection -3- and unclip it -a-.
8. Turn the fuel pump approx. 90° to the left until it disengages at the tank floor. Remove the fuel pump from the tank.





Turning the pump

Installing fuel pump

1. Place the pump in the holder on the tank floor and turn it approx. 90° to the right until it is seated securely.





Turning the pump

2. Connect the sucking jet pump connections -1 and 2- at the fuel pump. These must lock with an audible click.





Connecting sucking jet pump connections

3. Connect the connection -3- until it engages securely.
4. Fit a new seal in the opening of the tank at the left and right. => Seal





Seal

5. Pull the fuel line on the pressure regulator through the fuel tank to the left connection unit using the attached piece of wire or similar item.
6. Clip in the fuel line -3- on the left connection unit.





Fuel line on left connection unit

7. Connect all connections on the underside of the right connection unit.
8. Insert the left and right connection unit into the tank. When doing so, make sure that the plastic lugs are pointing forward.

Subsequent work

1. Close the tank. To do this, fit the sheetmetal ring on the left and right connection unit and tighten using special tool wrench T10202. => Cap => Tightening torque: 145 Nm (107 ftlb.)+/-5 Nm (+/-3.5 ftlb.)





Cap

2. Fit all connections for the right connection unit (fuel lines, ventilation tubes and electric connectors). => see figure





Fuel supply and connection points at right connection unit

3. Plug in electric plug connection for the left connection unit.





Connector for left connection unit

4. Fit the left lid (figure shows both lids). Then tighten the four fastening nuts to => Tightening torque: 10 Nm (7.5 ftlb.). Refit carpeted floor and fix in place with double-sided adhesive tape.





Fastening nuts on caps

5. Install rear seat. -> 724819 Removing and installing rear seat - section on "Installing" 724819 Removing and installing 1/3-split folding rear seat 724819 Removing and installing 2/3-split folding rear seat
6. Fill the fuel tank. -> 200317 Draining and filling fuel - section on "Filling" Procedures
7. Close the filler flap.
8. Connect the battery. -> 2X00IN Work instructions after disconnecting the battery 2X00IN Work instructions after disconnecting the battery