Instructions
Chassis / Fuel System / Fuel Delivery / DA-RM-04K002-02-002 - Remove/Install fuel pump
Preparation work
1.     
2.     
3.     
4.     
Care Point: Remove the left side only.
5.     
Care Point: Remove the left side only.
6.     
7.     
8.     

WARNING!
 
Risk of explosion, poisoning and injury working with fuel!
Fuels are highly flammable and toxic if inhaled. Fuel vapours are explosive, invisible and spread out at floor level. This vapour is poisonous when inhaled and has an anesthetizing effect in high concentrations. Fuel can cause damage to skin. For example, skin is degreased when it comes into contact with gasoline fuel.
Observe the national safety precautions and regulations.
Keep fuel away from fire, open light or ignition sources.
Ensure the work place is adequately ventilated.
Never drain or pour in fuels over assembly pits.
Store drained fuel in a suitable and sealed vessel.
Immediately eliminate any fuel which has flowed out.
Conducting work on a vehicle with open flames (e. g. welding etc.).
Before carrying out this work, remove relevant parts of fuel system and seal open fuel lines with plugs.
 

WARNING!
 
Possible fluid spills from vehicle systems during repairs or maintenance.
Risk of thermal incidents, slip hazards, corrosion of electrical components, failure of electrical or mechanical components or unwanted odours.
Always limit fluid spills and fully clean the spilled fluid after repairs or maintenance.
 

Remove fuel pump
1.  
Detach pipe ties (1).
 
2.  
Disconnect hose (2).
 
3.  
Disconnect electrical connectors (3).
 

 
Care Point:
Bolt (4) fitted to fuel tank will be an 8mm across flat type.
If the bolts require replacement, the spare parts catalogue defines bolts which are 7mm across flats.

 
4.  
Remove bolts (4). (M5x16) 5 Nm
 
5.  
Partially remove flange (5).
 

6.  
Disconnect electrical connectors (6).
 
7.  
Disconnect hose (7) from both ends and remove.
 

8.  
Release catches (8).
 

9.  
Remove fuel pump (9) from tank.
 


Install fuel pump
 
Care Point:
Replace flange O-ring.

Care Point:
Make sure the male end of ALL quick connectors are lubricated with SAE 30 oil before re-connecting.

Care Point:
Make sure fuel pump assembly is correctly located into mount.

 
1.  
Install components in reverse order.
 

   
   
   Note