Removal and Replacement

Special Tool:

SPECIAL TOOL
Special tool# 000 589 71 03 00 or equivalent is needed to perform this procedure.

Replacing Fuel Pump# 2 Check Valve:

REMOVAL AND REPLACEMENT
1. Disconnect the negative battery pole.
2. Release fuel tank pressure by removing the fuel cap.
3. Examine seal (41). Replace as needed.
4. Empty fuel tank (50) with suitable equipment.
5. Release cup seal (55).
6. Remove fuel tank lining and left/right side trunk lining.
7. Remove protective box (69) for fuel pump pack.
8. Pinch fuel suction hose (53).
9. Detach fuel suction hose (53) with special tool# 000 589 71 03 00 or equivalent. Collect remaining fuel in fuel safe container.
10. Remove fuel return hose (74). Collect remaining fuel in fuel safe container.
11. Remove vent line (64). Collect remaining fuel in fuel safe container.
12. Remove fuel suction hose (53). Collect remaining fuel in fuel safe container.
13. Disconnect fuel gauge sending unit el. connector (B4).
14. Remove nuts (38) at fuel tank. Pay attention to the washers (35).
15. Remove fuel tank (50). Use wooden or plastic wedge to loosen.
16. Renew sound deadening strip (29, 30).
17. Remove fuel strainer (23). Clean and check for condition, replace as needed.
18. Replace O-rings (26).
19. Install in reverse order. Check for the following:
a. Torque fuel strainer (23) to:

39 Nm (29 ft. lb.)

b. Torque nuts (38) to:

21 Nm (15.5 ft. lb.)

20. Run engine and check for leaks.