"VCC-131782 EN 2010-08-26"

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 .
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.

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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.

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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 999 5561 . Move the shaft to one side.

Standard bolts for front and rear CV joints and

balancer bolt for rear CV joint

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Note! Before removing the propeller shaft from

the driver:Carefully
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 998 5972 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.

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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 1203219-
1203219-9 (door button
200/700/900) to prevent fuel spills.

Remove:
- fuel lines from the fuel pump and ejector
pump, use special tool 999 5666
- fuel line attachments between the fuel

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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 999 5485 .

Fitting the fuel pump units

Fitting the fuel pump units

Fit:
- 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.

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Tighten the nuts to 40 Nm.

Nm Use special tool
999 5673 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.

Fit:
- 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 (left-

hand side).

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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 1161351-0, 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.
Nm
Tightening the tank strap attachments

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Tighten the tank strap attachments on both

sides.
Remove the lifting table.

Fitting the fuel tank EVAP lines

Fit:
- 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.
Nm Then tighten
opposite bolts to 30 Nm.
Nm Use holder 999 5561
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 999 5659 and
Normal position , chapter
General, General information in
service manual, section 4 (43,
46), AWD (All Wheel Drive), 850
1997-.
Connect the left-hand three-way
branching to the left-hand jack
attachment.
Fit the longitudinal stay brackets

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and the jack attachments using

new bolts.
Tighten the three bolts for the
longitudinal stay bracket to 65
Nm + 60°.
60°
Tighten the bolt through the jack
attachment to 105 Nm + 90°.
90°
Fitting the exhaust pipe

Fit:
- rear exhaust pipe
- silencers.
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

Fit:
- 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.

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Tighten the screws.

Fitting the rear wheels

Fit:
- wheel arch liner and mudflap on rear edge
on right-hand side.
- rear wheels.
Refill the fuel tank.
Test drive and perform functional checks.

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