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Fuel pump, 4WD

Fuel pump, 4WD

Warning

The work involved in removing the fuel pump requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:

• Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.

• Absolutely No Smoking!

• Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.

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

• Wear protective goggles.


Important

Be particulary observant regardning cleanliness when working on the fuel system. Loss of function may occur due to very small particles. Prevent dirt and grime from entering the fuel system by cleaning the connections and plugging pipes and lines during disassembly. Use 82 92 948 Plugs, A/C system assembly. Keep components free from contaminants during storage.


To remove


1. Remove Fuel tank, 4WD .

2. To prevent dirt entering the fuel system, clean the outside of the tank if necessary before removing the fuel pump.

3. Undo the fuel pump connector (A), pressure sensor connector (B) and the carbon canister quick coupling (C).


4. Use a plate as protection between the rivet and the tank. Use an 8 mm bit to carefully drill away the rivet head (D) and press out the rivet.

5. Remove the protective cover (E) using a ½" handle and turning anti-clockwise.

6. Remove the fuel pump. Use tool 83 96 194 Fuel pump removal/fitting tool to undo the fuel pump circlip.

7. Lift up the fuel pump slightly, undo the quick coupling (A) for the tank's vent from the fuel pump and the quick coupling (B) of the ejector hose.


8. Carefully lift up the fuel pump and place it in a receptacle.

Important

Take care not to damage the fuel level sensor.


9. Remove the seal (A).



To fit


1. Fit a new seal (A).

2. Fit the quick coupling (B) of the ejector hose. Lift up the ventilation hose and lower the fuel pump slightly. Secure the ventilation hose to the pump housing and connect quick coupling (A) to the pump cover. Lower the fuel pump carefully into the tank.


3. Make sure the recesses (A) in the tank connection are in line with the corresponding lugs on the pump cover.


4. Ensure that the pump is in the right position according to the following:

• guide lugs are in the right position in relation to the tank recesses (A).

• the fuel pump's connector (B) is in line with the rear long side of the tank.

5. Check that the seal is properly positioned. Tighten the fuel pump fixture using 83 96 194 Fuel pump removal/fitting tool .

6. Fit the protective cover (E) on the fuel pump circlip, turning clockwise. Fit a new rivet (D) to lock the protective cover in place.

7. Attach the fuel pump connector (A), pressure sensor connector (B) and the carbon canister quick coupling (C).


8. Secure loose cables and lies to the recesses on the fuel tank.

9. Fit Fuel tank, 4WD .