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Fuel pump

Fuel pump

Warning

Removal of the fuel pump involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work:

• Work only in a well-ventilated area! If approved equipment for the extraction of fuel vapours is available, be sure to use it.

• Wear suitable gloves! Prolonged contact with fuel can cause skin irritation or dermatitis.

• Keep a class BE fire extinguisher near at hand! Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits.

• No smoking anywhere in the vicinity.

• Wear protective goggles.


To remove

Important

The car should be parked on a level surface. If the tank is full and the car is jacked up at the rear when the pump is removed, it is very likely that fuel will run out.

Place protective paper over the carpeting when the pump is removed as there is a risk of fuel spilling out.



1. Raise the rear seat cushions and fold the carpeting out of the way.


2. Remove the fuel pump cover.

3. Unplug the upper connector.

Important

The connector on the pump must not be removed.


4. Carefully work loose the check valves with fuel lines from the pump (move the yellow hooks to one side with a screwdriver). The check valves are connected to the pump with quick-release couplings. The white ones are the delivery side and marked "Pressure" on the pump. The black ones are the return side and are marked "Return" on the pump. Move them out of the way and secure them under the plate seam.


5. Remove the screw ring. Use the key, part no. 83 94 462.


6. Lift up the pump until the top of it is about 50 mm above the fuel tank. Then turn the pump clockwise about 80° and carefully remove it. Hold paper or a cloth ready to catch any fuel that spills out.


7. Transfer the pump to a suitable receptacle and pour off the fuel.


To fit


Note

Spray the connectors with Kontakt 61, part no. 30 04 520, before connecting them.



1. Clean sealing surfaces.

2. Fit a new O-ring in the groove in the tank.

3. Carefully lower the pump into its correct position, making sure that the alignment marks on the tank and fuel pump are opposite each other. Carefully press the pump down into position.


Important

It is essential to the operation of the fuel level sensor for the pump unit to be correctly positioned.


4. Lubricate the screw threads on the pump cover and the upper edge of the pump with acid-free vaseline to prevent the pump turning when the screw ring is tightened.

5. Fit the screw ring and tighten it with the tool, part no. 83 94 462.

Tightening torque: 75 Nm (55 lbf ft).

6. Inspect the O-rings on the fuel line connections, lubricate them with acid-free vaseline and connect the fuel lines to the pump.


7. Make sure that the yellow hooks have snapped in place over the connections.

8. Plug in the connector.

9. Check that the pump works properly and that it does not leak.

10. Fit the fuel pump cover, return the rear seat cushions to their places and fold back the carpeting.


Checking the fuel gauge float arm position


With the pump placed on a level surface, the distance between the surface and the bottom of the float should be 0-3 mm.

The sensor resistance should be:

Tank empty, float in bottom position: 50 ± 1.5 ohms.

Tank full, float in top position: 425 ± 6.5 ohms.