Fuel Reservoir: Service and Repair

To replace the Fuel Reservoir:

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.

Fuel Pump:

1. 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.

Fuel Delivery Components:

2. Working beneath the car, disconnect the harness connector from the fuel pump.
3. Temporarily pinch shut the supply line that comes from the transfer pump to the fuel reservoir. Ready container to catch spilling fuel.
4. Disconnect the output fuel line to drain the fuel reservoir. Remove the cap nut, fuel line and the two sealing washers.
5. Remove the bolts holding the fuel pump/reservoir to the body and lower the assembly.
6. Label and remove the fuel hoses to the fuel reservoir.
7. Remove the fuel filter from the mounting bracket.
8. Remove the three mounting screws from the fuel pump retaining ring and pull the fuel pump assembly from the fuel reservoir.
9. 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.
10. Install the fuel filter into the mounting bracket.
11. Reconnect the fuel lines to the reservoir. Use new hose clamps.
12. Position pump/reservoir assembly to body and install fuel pump/reservoir mounting bolts.
13. Install the fuel lines to the pump, accumulator and filter using new sealing washers on either side of banjo fittings. Torque fittings to:

Pump cap nut
15 ft.lbs. (20 Nm)

Accumulator fittings
20 ft.lbs. (27 Nm)

Fuel filter inlet
18 ft.lbs. (25 Nm)

Fuel filter outlet
15 ft.lbs. (20 Nm)

14. Reinstall the negative (-) battery terminal.
15. START the car and check for leaks, repair any leaks immediately.