Installing Fuel Pump

Information 

• The fuel system must be depressurised before starting work on it. 
• Only work on the fuel system in well-ventilated rooms. 
• Any seals that were removed must always be replaced. 
• Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors. 
• Catch escaping fuel using suitable aids and dispose of it in accordance with the applicable national laws. 

Information 

• The guiding rod of the fuel level sender must not be deformed. 
• If the guiding rod is deformed, the fuel level sender must be replaced. 

1. Replace fuel pump seal.
2. Only for fuel pump with sucking jet pump -1-  :
   1. 2.1  Guide the line -2-  of the sucking jet pump -1-  into the fuel tank and position it at the baffle plate -3-  .

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      Sucking jet pump line

3. Only for fuel pump with sucking jet pump -1-  :
   1. 3.1  Guide the chamber -2-  of the fuel pump into the fuel tank, connect sucking jet pump -1-  to the line and clip it into the chamber -2-  (-arrow A-  ). Check that it locks correctly.
   2. 3.2  Guide the fuel pump into the fuel tank -arrow B-  .

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      Fuel pump (with sucking jet pump)

   Information 

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   Installation position of fuel pump (similar to illustration)

   • The fuel pump -1- fits - only at one position on the fuel tank flange. 
4. Secure the fuel pump.
   1. 4.1  Position the fuel pump and fit the lock -1-  .
   2. 4.2  Tighten the lock -1-  using > T10202 - wrench-2-  in -direction of arrow-  .
      • Tightening torque 110 Nm (81.5 ftlb.) 

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   Fuel pump lock

5. The arrow on the lock -1-  must be at the previously marked position again after tightening.

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   Marking lock

6. Connect connections to fuel pump -1-  .

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   Fuel pump connections

   1. 6.1  Connect and lock electric plug connections -2 and 3-  .
   2. 6.2  Position line bracket -4-  in the guide on the body.
   3. 6.3  Connect fuel lines -5 and 6-  and make sure they are latched correctly.
7. Close the fuel pump cover -2-  and fit protective mat -1-  .

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   Fuel pump cover