Fuel Pump, Replacement

Special tools:
999 5465, 5485



WARNING:
No sparks or flame in work area.


A1
Disconnect battery


A2
Drain fuel system as described on page 115 of manual.


A3
Tilt right-hand rear seat forward.


A4





Remove:
- luggage compartment mat and right-hand wheel housing panel

- cover over fuel pump nut


A5





Disconnect fuel pump connector



A6
Check color code markings on hoses and pump

Note:
Delivery hose is marked with yellow tape, corresponding to the color code on the pump.

A7





Carefully undo quick-release couplings on delivery and return hoses using tool 5465. Slide outer sleeve of coupling upwards without squeezing sleeve

A8





Remove fuel pump unit nut

Use tool 5485.


A9
Remove pump unit and rubber seal

Note:





Lift unit straight upwards. Do not grip pipe connections with pliers or other sharp tool as damage to connections may result in fuel leakage.

Refit pump unit nut, otherwise connection branch on tank may swell, causing difficulty in refitting nut when reinstalling unit.

Installation of pump

A10
Use new, dry seal, p/n 3531426-9. Ensure that seal is correctly seated. Lubricate flat, upper surface of inner face and narrow, outer edge of seal with thin coating of petroleum jelly.


A11
Grease upper edge of seal to prevent it sticking to nut


A12





Install pump unit (as illustrated)



A13
Install pump unit nut





Tighten to 40 N-m (30 ft.lb) using tool 5485.

Grease delivery and return hoses lightly with petroleum jelly.

Reconnect delivery and return hoses to pump unit. Delivery hose is marked with yellow tape, corresponding to color coding on pump flange.

Reconnect quick-release couplings, ensuring that couplings are straight. Press against flat surface of pump, ensuring that O-rings are not damaged.

Note:
Ensure that leads are correctly positioned.


A14
Install:





- panel on right-hand side
- cover over pump unit nut
- luggage compartment mat


A15
Raise right-hand rear seat


A16
Reconnect battery


A17
Re-enter radio code



WARRANTY STATEMENT:
Claims may be submitted under the New Car Limited Warranty, using:

Oper. No. Labor Description Time Allowance

233122 Fuel pump, replace 0.6 hr