FWD
Fuel Pump, Removing And Installing
CAUTION: To remove the Fuel Pump (FP), the fuel tank may only be filled to a maximum of 3/4. Empty fuel tank if necessary.
Recommended special tools and equipment
- 3217 ring nut spanner
- VAS5190 fuel siphoning device
Empty Fuel Tank
Observe safety precautions. Fuel Systems
Observe rules for cleanliness. Vehicle Damage Warnings
CAUTION: Observe safety precautions when disconnecting the battery.
- Disconnect battery Ground (GND) strap with the ignition switched off.
CAUTION: Secure Ground (GND) wire of VAS 5190 to a blank portion of the chassis.
- Pull cone piece -2- from shaft piece -1- of VAS 5190.
- Using insulating tape, apply a mark -arrow- on hose at length a = 1465 mm from end of suction hose.
- Remove fuel filler cap from fuel filler tube.
- Screw shaft piece -1- of VAS 5190 fuel siphoning device on to fuel filler tube of fuel tank.
- Now slide suction hose as far into fuel tank until the mark applied earlier -arrow- stands on shaft piece.
NOTE:
- If using a siphoning device without shaft piece, proceed principally in the same manner.
- In this case, apply a mark -arrow- on hose at length a = 1400 mm from end of suction hose using insulating tape. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube.
- If the hose can only be inserted with difficulty, smear it thinly with engine oil. Never use lubricants containing silicon.
- Drain fuel tank through fuel filler tube.
- Carefully remove siphoning hose.
Removing
Sedan:
- Remove luggage compartment lining.
- Push forward the right backrest of rear seat, if necessary.
Avant:
- Remove left 1/3 backrest.
- Remove left side trim in luggage compartment and dirt tray.
All:
- Remove cover for connector flange (arrows).
- Release and disconnect harness connector -1-.
- Disengage electrical harness connector -2- and lay it aside.
CAUTION: Fuel system is under pressure. Before opening system, place rags around the connection. Then release pressure by carefully loosening connection.
- Mark and disconnect fuel supply line -1- and fuel return line -2- (press release tab).
- Use ring nut spanner 3217 to remove union nut.
- Lift out fuel pump with sealing ring slightly from opening of fuel tank
- If Fuel Pump (FP) is still inserted in fuel tank, slide connector flange slightly to the side.
- Grasp through the gap between connector flange and installation opening in fuel tank and release suction jet pump -1-.
NOTE: Fuel tank is depicted as cut-out section.
- Pull suction jet pump -1- upward with suction jet pipe -2- still connected.
- Disconnect suction jet pipe from suction jet pump (press release button).
- Remove suction jet pump.
- Remove Fuel Pump (FP).
Installing
Installation is the reverse of removal, noting the following:
- Connect suction jet pipe -2- to connection for suction jet pump -1-.
- Insert Fuel Pump (FP) into fuel tank.
- Clip in suction jet pump -1- on Fuel Pump (FP). To do so, insert hand into gap between connector flange and installation opening of fuel tank.
- Suction jet pump must engage audibly
- Insert new, dry seal for connection flange into opening of fuel container.
- Note installation position of Fuel Pump (FP):
- Marking on connector flange -2- must align with marking on fuel tank -1-.
- Tighten union nut for connector flange.
- Install fuel supply line -1- and fuel return line -2- according to the marking.
- Connect electrical harness connectors.
- Observe safety precautions after connecting the battery.
Tightening torques
Component Nm
Union nut for Fuel Pump (FP) 80
Battery terminal to battery post 6
Final procedures
After re-connecting the voltage supply, the following work steps must be performed in the mentioned sequence:
1 - Check DTC memory, "Mode 3: Check DTC memory".
2 - If necessary, erase DTC memory, "Mode 4: Reset/erase diagnostic data".
3 - Generate readiness code.
- End diagnosis and switch ignition off.