16 14 010 Removing and installing/replacing fuel pump (petrol/gasoline, N52)

Special tools required:

See 16 FUEL SUPPLY SYSTEM , 61 GENERAL ELECTRICAL SYSTEM .

16 1 020
61 0 300
61 0 307

IMPORTANT: Ensure adequate ventilation in the place of work!
Ensure absolute cleanliness when working on the open fuel tank.
Contaminants in the fuel tank can impair driving operation or may even result in vehicle breakdown!

Necessary preliminary tasks:

Draw off fuel from fuel tank, see 16 00 005 Draining and filling fuel tank .
Remove rear seat bench, see 52 26 005 REMOVING AND INSTALLING/REPLACING REAR SEAT (THROUGH-LOADING SYSTEM) .

Release screws (1) and remove cover (2) from right side of fuel tank.

Fig 1: Cover Screws

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Unlock and detach plug (1), fuel feed line (2) and service vent line (3).

Fig 2: Plug And Service Vent Line

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Release screw cap with special tool 16 1 020 and remove service cap.

Installation:

Tightening torque: 16 14 2AZ, see 16 14 FUEL PUMP .

Fig 3: Special Tool 16 1 020

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Installation:

Service cap can only be installed in one position.

When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.

During torque tightening, notch (3) on screw cap can be clearly heard and felt to engage toothed segment (4) on fuel tank.

Replace rubber gasket.

Fig 4: Service Cap Lug And Notch

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IMPORTANT: Make sure that tab (1) of adapter ring lies completely in recess (2).

Fig 5: Tab Of Adapter Ring

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Carefully raise service cap (4) on right.

Unlock and detach fuel line (2).

Detach vent line (3).

Disconnect connector (1).

IMPORTANT: Carefully release quick-release fasteners and detach.
Make sure quick-release fasteners are correctly engaged.
Test the quick-release fasteners by pulling on them.

Fig 6: Service Cap, Fuel Line, Vent Line And Connector

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Installation:

Cable (1) must be laid in a loop around the corrugated tube (2).

Cable must not restrict freedom of movement of lever-type sensor!

Fig 7: Cable And Tube

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Unlock and disconnect plug housing (1) using a screwdriver (2).

Fig 8: Plug Connection

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Unpin cables (1) issuing from lever-type sensor on blue plug using special tool 61 0 307 from special tool kit 61 0 300 .

NOTE: Plug connection on fuel pump must not be disconnected!
When the fuel pump is replaced, the cables and the blue plug are included in the delivery specification.

Fig 9: Cables And Special Tool 61 0 307

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Press retaining lug (2) together simultaneously in direction of arrow and detach fuel line (1) from pressure regulator.

Fig 10: Pressing Retaining Lug

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Unlock quick-release fastener (1) by pressing both white surfaces and detach.

Fig 11: Unlocking Quick-Release Fastener

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Press retaining lug (1) in direction of arrow towards rear and lift out fuel pump with surge chamber (2).

Installation:

Fuel pump can only be installed in one position.

Make sure lug (4) of mounting engages opening in fuel pump.

Make sure fuel pump (2) is correctly positioned in guides (3).

Fig 12: Pressing Retaining Lug

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