To replace the Main Fuel Pump:
WARNING: Fuel will be expelled during this procedure. Place a large container under work area to catch spilling fuel, use a clean rag to soak up any spilled fuel around container. Do not disconnect any wires that could cause electrical sparks. Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy.
Disconnect the negative (-) battery terminal.
CAUTION: Absolute cleanliness is essential when working with fuel circuit components of CIS-E Motronic. Even a minute particle of dirt can cause major trouble if it reaches the fuel distributor or the fuel injectors. Before disconnecting any of the fuel line connections, throughly clean the unions. Always use clean tools.
Working beneath the car, disconnect the harness connector from the fuel pump.
Temporarily pinch shut the supply line that comes from the transfer pump to the fuel reservoir. Ready container to catch spilling fuel.
Disconnect the output fuel line to drain the fuel reservoir. Remove the cap nut, fuel line and the two sealing washers.
Fuel Delivery Components
Remove the three mounting screws from the fuel pump retaining ring and pull the fuel pump assembly from the fuel reservoir.
Moisten the new O-ring with fuel and install it over the fuel pump. Make sure the fuel pump filter screen is clean, then install the pump into the fuel reservoir. Secure the retaining ring with the three screws. Tighten the screws evenly, checking to see that the fuel pump is correctly seated.
Reconnect the fuel line and the harness connector. Use new sealing washers on either side of the banjo fitting.
Torque the cap nut to: 15 ft.lbs. (20 Nm)
Reinstall the negative (-) battery terminal.
START the car and check for leaks, repair any leaks immediately.
Saturday, May 29th, 2010 AT 2:15 PM