Fuel Pump: Service and Repair

Fuel pump, replacement

Special tools:
999 5622 Wrench 999 5622 Wrench

Fuel tank, draining
- Drain the fuel tank. See Draining the fuel tank Draining The Fuel Tank.

The fuel pump's (FP) protective cover, removing




- Move the front seats as far forward as possible.
- Fold the rear seat forward.
- Pull the floor carpet forward.
- Remove the four screws. Remove the protective cover.
- Remove the splash guard.

Fuel pump (FP), removing





Note! Ensure that the ventilation is good.

Note! Note the connections for the fuel lines to avoid later confusion.

- Disconnect the connector (A).
- Release the fuel lines by pressing in the catches and pulling out the lines.
- Wipe up any spilled fuel using a rag.
- Move the fuel lines and connectors to one side.
- Remove the cap nut. Use special tool 999 5622 Wrench 999 5622 Wrench.

Note! Replace fuel pump (FP) immediately because the threaded collar swellsalternatively, reinstall the cap nut temporarily.The swelling can cause problems when reinstalling the cap nut.

Fuel pump, installing




- Check the gasket. Replace the gasket if necessary
- Install the cap nut on the pump unit.
- Install the pump unit. Ensure that the arrow points towards the marking (B) on the fuel tank.
- Install the cap nut using special tools 999 5622 Wrench 999 5622 Wrench.
Press the cap nut down firmly when installing it.
Tightening torque 50 Nm.
- Reconnect the connector (A)
- Carefully reconnect the fuel hoses. Check that the quick-release connectors are secure by pulling them.
- Remove the pump trolley. Fill the fuel injection system, see Draining the fuel tank Draining The Fuel Tank.

Fuel pump's (FP) protective cover, installing




Reinstall / reconnect:
- The protective cover.
- The protective cover with four screws.
- The floor carpet under the sill trim panel and on the sides of the backrest.
- Backrest, rear seat.

Post work (only applies to the USA)

Identification of level sensor

Caution! New software must be downloaded: SW 30623218, if an older version of fuel pump is replaced with a newer version.




Older versions of level sensor have a sliding contact (1).




New versions of level sensor have two sliding contacts (2).