Fuel pump unit, changing

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Gary Patterson
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1(11) Fuel pump unit, changing Special tools: 981 2270, 981 2273, 981 2282, 998 5972, 999 5484, 999 5485, 999 5561, 999 5666, 999 5673 Safety See first Safety regulations for handling fuel.

with Fitting the fuel pump units and then Fitting the rear suspension assembly. Draining the fuel system To drain the fuel system, see Draining fuel injection system.

1 1(11) Fuel pump unit, changing Special tools: , , , , , , , , Safety See first Safety regulations for handling fuel. Preparation Draining the fuel tank To drain the fuel tank, see Draining the fuel tank AWD and 2WD/ORVR (IE00) If you have drained the tank using the method for a malfunctioning fuel pump continue with Fitting the fuel pump units and then Fitting the rear suspension assembly. Draining the fuel system To drain the fuel system, see Draining fuel injection system. Removing the luggage compartment floor Remove the front and rear luggage compartment floor. Unplugging the connectors Undo the ABS sensor and fuel level sensor connectors. Remove the connectors' holder and the front cover. Feed the leads through the hole. Detaching the filler pipe Remove the lock ring from the rubber gaiter. Press the rubber gaiter and filler pipe into the wheel housing.

Removing the protective covers in front of fuel tank Remove: - protective covers at front edge of fuel tank

2 2(11) Disconnecting the rear wheels Remove: - rear wheels - right-hand wheel arch liner and mudflap. Disconnecting the fuel tank EVAP lines Remove the protective cover from the fuel lines. Removing the protective covers in front of fuel tank Remove: - protective covers at front edge of fuel tank (three plastic nuts on each cover) - all pipes from the plastic clips on the fuel tank. Removing the exhaust pipe Remove the rear exhaust pipe and silencers.

3(11) Detaching the longitudinal stay mountings Detach the longitudinal stay mountings from the body.

Remove: - bolts for jack attachment and longitudinal stay mounting in body, both sides - engine lift. Undo: - three-way branching on left-hand jack attachment.

Tie the jack attachment to the longitudinal stay brackets (A). Use a cable tie. Removing the propeller shaft Mark the propeller shaft in relation to the driver. Note!

3 3(11) Detaching the longitudinal stay mountings Detach the longitudinal stay mountings from the body. Position an engine lift gently against the longitudinal stay mounting. Remove: - bolts for jack attachment and longitudinal stay mounting in body, both sides - engine lift. Undo: - three-way branching on left-hand jack attachment. - front brake pipe from the 4 clips under the car. Removing the hand brake cable Remove the hand brake cable from the jack attachment by drilling out the pop rivet (B). Tie the jack attachment to the longitudinal stay brackets (A). Use a cable tie. Removing the propeller shaft Mark the propeller shaft in relation to the driver. Note! Note the length and location of the bolts on the propeller shaft CV joints. See the table below (standard bolts for front and rear CV joints and balancer bolt for rear CV joint). Remove the propeller shaft bolts. Use holding tool Move the shaft to one side. Standard bolts for front and rear CV joints and balancer bolt for rear CV joint

4(11) Note! Before removing the propeller shaft from the driver:carefully mark the position of the propeller shaft in relation to the driver. Check also whether balancer bolts are fitted.

5 mm white marking (lock paint) Balancer bolts length 55 mm blue marking (lock paint) Balancer bolts length 57.

4 4(11) Note! Before removing the propeller shaft from the driver:carefully mark the position of the propeller shaft in relation to the driver. Check also whether balancer bolts are fitted. Where applicable, note the position and length of the balancer bolts. Standard bolts length 50 mm red marking (lock paint) Balancer bolts length 52.5 mm white marking (lock paint) Balancer bolts length 55 mm blue marking (lock paint) Balancer bolts length 57.5 mm black marking (lock paint) Balancer bolts length 60 mm yellow marking (lock paint) Balancer bolts length 62.5 mm grey marking (lock paint) Balancer bolts length 65 mm green marking (lock paint) Balancer bolts length 70 mm red marking (lock paint) Note! If the propeller shaft is refitted without the rear CV joint being changed or the driver on the differential being removed or changed, proceed as follows: Fit the propeller shaft according to the marks made on removal (see the section above). Use new bolts of the same length as those removed. If the propeller shaft is changed, the new shaft should be fitted with new, only standard length bolts. Lowering the torque tube Position engine lift against the torque tube. Remove the bolt and lower the torque tube with the engine lift. Removing the rear suspension assembly Positioning the lifting table Place the lifting table with fixture under the tank and link arms. See illustration. Caution! Secure the front part of the differential to the lifting table. This prevents the rear suspension from tipping backwards when lowered.

5(11) Removing the tank strap bolts Remove the tank strap bolts from both sides. Removing the rear axle member bolts. Remove the bolts securing the rear axle member to the body on both sides.

5 5(11) Removing the tank strap bolts Remove the tank strap bolts from both sides. Removing the rear axle member bolts. Remove the bolts securing the rear axle member to the body on both sides. Lowering the rear suspension with fuel tank Carefully lower the rear suspension and fuel tank about 30 cm. Check that the fuel filler pipe is clear of the wheel arch lining. Note! Check also that the fuel line between the fuel level sensor and the ejector pump does not foul on the body during lowering. Note! Check that the brake pipes are clear. Removing the fuel lines. Caution! Note the position on the fuel lines on the tank so that they are given corresponding positions on the new tank. Unhook the fuel lines from their mountings. Caution! Plug the disconnected fuel line fittings with part number (door button 200/700/900) to prevent fuel spills. Remove: - fuel lines from the fuel pump and ejector pump, use special tool fuel line attachments between the fuel

6 6(11) pump and fuel filter. Note! Do not remove the fuel line between the fuel pump and the ejector pump. Removing the fuel lines from the clips Remove the return line from the ejector pump (left-hand side). Remove the pump units Remove: - pump unit on left-hand side - pump unit on right-hand side. Use specail tool Fitting the fuel pump units Fitting the fuel pump units - new washers - left-hand pump unit - right-hand pump unit Grease all contact surfaces of the pump units' retaining nuts with vaseline. Note! No vaseline must be applied to the nut threads.

7 7(11) Tighten the nuts to 40 Nm. Use special tool as a holder. To ensure the correct positioning of the pumps, the pointer on the tool must be between the markings on the fuel tank. Note! Make sure the pump units are correctly positioned so that the fuel gauge shows the correct value. Fitting the rear suspension assembly Fitting the fuel lines Position and secure the fuel lines to their mountings in the same order as they were removed. - Fuel line attachments between the fuel pump and fuel filter. - fuel lines from the fuel pump and ejector pump. Fitting the fuel lines to the clips Fit the return line from the ejector pump (lefthand side).

8(11) Fitting the hand brake cable Raise the rear suspension about 10 cm. Remove the cable tie (A). Fit the hand brake cable with clips, use a pop rivet (Ø 4 mm) (B).

8 8(11) Fitting the hand brake cable Raise the rear suspension about 10 cm. Remove the cable tie (A). Fit the hand brake cable with clips, use a pop rivet (Ø 4 mm) (B). Raising the rear suspension with fuel tank Raise the rear suspension and fuel tank. Make sure the fuel filler pipe does not foul the wing liner. Make sure the fuel line is clear of the body and that the fuel level sensor line does not get caught in the fuel strap brackets. Lift up the tank fitting lines and fuel pump lines through the body (hatch). Caution! Secure the front part of the differential to the lifting table. This prevents the rear suspension from tipping backwards when lowered. Note! Check also that the fuel line between the fuel level sensor and the ejector pump does not foul on the body when the rear suspension is lifted. Adjust and secure the filler pipe's crash protection bracket. Fitting the retaining bolts for the rear axle member. Apply a couple of drops of threadlock, part number , to each bolt. Fit all the retaining bolts for the rear axle member. Note! Before fitting the rear axle to the body, measure the distance between the rear axle member guide Ø 16.5 mm holes (A) outside the rear retaining bolts, and the Ø 16 mm holes furthest to the rear on the side members. The distance between the holes should be 595 mm ± 2 mm. Tighten the outer bolts to 80 Nm and the centre bolts to 50 Nm. Tightening the tank strap attachments

Fitting the propeller shaft and driver Fit the propeller shaft to the driver. Note! Fit the propeller shaft as marked earlier. Refit the bolts in their original positions.

9 9(11) Tighten the tank strap attachments on both sides. Remove the lifting table. Fitting the fuel tank EVAP lines - brake pipe in the 4 clips - fuel and EVAP lines - lines to protective cover - protective cover, use new nuts and washers - protective covers in front of fuel tank. Fitting the propeller shaft and driver Fit the propeller shaft to the driver. Note! Fit the propeller shaft as marked earlier. Refit the bolts in their original positions. Check the contact surfaces of the viscous coupling and propeller shaft drivers are clean. Tighten opposite bolts to 8 Nm. Then tighten opposite bolts to 30 Nm. Use holder Start by tightening the same bolt both times. Fitting the longitudinal stay mountings and jack attachments Fit the front longitudinal stay mountings and the jack attachments to the body. Press up the link arms to their normal position. Use of tensioner and Normal position, chapter General, General information in service manual, section 4 (43, 46), AWD (All Wheel Drive), Connect the left-hand three-way branching to the left-hand jack attachment. Fit the longitudinal stay brackets

10 10(11) Fitting the exhaust pipe - rear exhaust pipe - silencers. and the jack attachments using new bolts. Tighten the three bolts for the longitudinal stay bracket to 65 Nm Tighten the bolt through the jack attachment to 105 Nm Note! Check that there is clearance to the heat shields. Fitting the filler pipe Fit the fuel filler pipe to the body with the rubber gaiter and lock ring. Fitting the hatches and connections to the tank fitting - front and rear hatch in the body and the connector holder. Make sure the rubber seal around the wiring is properly fitted when the rear hatch is fitted. - connectors to the tank fitting, fuel pump and ABS system. Positioning the luggage compartment floor mountings Position: - mounting at front edge of luggage compartment floor. Fit the screws along the rear edge. - hatch with the rear floor hatch.

11 11(11) Tighten the screws. Fitting the rear wheels - wheel arch liner and mudflap on rear edge on right-hand side. - rear wheels. Refill the fuel tank. Test drive and perform functional checks.

FUEL PUMP UNIT, REPLACEMENT. Special tools: , , , , , , , ,

FUEL PUMP UNIT, REPLACEMENT. Special tools: , , , , , , , , FUEL PUMP UNIT, REPLACEMENT Special tools: 981 2270, 981 2273, 981 2282, 998 5972, 999 5484, 999 5485, 999 5561, 999 5666, 999 5673 Safety See first: Safety regulations for handling fuel See: Service Precautions