Without Turbo
FUEL PUMP, REMOVAL AND FITTINGCAUTION: When carrying out any work on the fuel tank, such as replacing the fuel pump or fuel level transmiller, make sure that the area is well ventilated.
If approved extraction equipment for petrol fumes is provided, make use of it. Wear suitable gloves, as prolonged contact with fuel can cause dermatitis.
To Remove:
1. Disconnect the negative battery cable.
2. Depressurize the fuel system by undoing the nipple on the fuel distribution pipe. Retighten the nipple afterwards.
3. To gain access to the fuel pump, remove the luggage compartment floor panel and the cover over the fuel pump.
4. Remove the clamp and disconnect the pump's electric leads and the fuel lines.
Note: Although the fuel system has been depressurized, a small amount of fuel will still escape from the connections,
5. Move the fuel lines aside and secure them by means of a cable tie to the rear wiring harness.
6. Apply tool 83 94 397 as shown in the Fig.
Pass the chain through the load-securing brackets on the luggage compartment floor. Secure the chain by means of a screwdriver as shown in the Fig.
7. Loosen the screw top and put the tool aside.
Unscrew the screw top by hand. Remove the rubber seal and lift up the pump while tilting the top part of it forwards and to the left. Allow as much fuel as possible to run out of the pump before lifting it up.
8. Lift the pump out of the tank and transfer it to a receptacle where the remaining fuel can run out.
To Fit:
1. Position the pump before placing it in the tank so that the pressure and return lines are in alignment with the longitudinal axis of the car. Tilt the pump assembly so that the ejector part is introduced into the tank first.
Position the pump inside the tank. Make sure that it is centered between the ribs on the bottom of the tank
and so that the mark on the top of the pump lines up with the mark on the tank.
2. Smear a new seal with acid-free petroleum jelly (Vaseline) and fit it inside the screw top as shown in the Fig.
The seal can also be fitted on the top of the pump if great care is taken to ensure that it is accurately positioned.
New rubber seal fitted inside the screw top.
3. Position the screw top so that the markings are in alignment. Press down hard and rotate the top half a turn.
4. Change the chain attachment points so that the chain is correctly positioned for tightening.
Apply the tool and press down on it so that the screw top is brought into contact with the flange of the tank opening.
Press down on the tool to bring the screw top into contact with the tank.
Note: To prevent the ejector pump from being damaged, the pump must be correctly positioned and not allowed to turn when the screw top is tightened.
Tighten it as far as it will go.
The position of the pump must not deviate by more than ±30° from the alignment marks.
5. Connect the fuel lines and fit the couplings with new 0- rings.
The return line (1) incorporating a non-return valve in the fitting is connected to the outlet nearest the front of the car and the pump line (2) to the outlet nearest the rear of the car.
6. Connect the electric leads and fit the locking clamp.
7. Connect the negative battery cable.
8. Check the operation of the pump and also check it for leakage.
9. Refit the circular cover and the luggage compartment floor panel.
