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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 coax the non-return valves and fuel lines away from the pump (push the yellow hooks to one side with a screwdriver). The non-return valves are secured with snap-on couplings to the pump. The white one is for the pressure side and is marked with "Pressure" on the pump. The black one is for the return side and is marked with "Return" on the pump. Place them out of the way under the plate seam.


5. Remove the screw ring, using special tool 83 94 462.


6. Lift the pump until its upper part is approximately 50 mm above the fuel tank. Then turn the pump clockwise approx. 80° and carefully remove the pump. Hold some paper or a cloth prepared to catch any fuel spills.


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


To fit



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 threads on the pump lid and the top of the pump with non-acidic vaseline to prevent the pump from turning when the screw ring is tightened.

5. Fit the screw ring and tighten it, using tool 83 94 462.

Tightening torque: 75 Nm (55 lbf ft).

6. Inspect and lubricate the O-rings on the fuel line connections with non-acidic vaseline and connect them to the pump.


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

8. Plug in the connector and spray it with a contact cleaner like Kontakt 61 (part No. 30 04 520).

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:

Empty tank, float at bottom: 50 ± 1.5 ohm

Full tank, float at top: 425 ± 6.5 ohm