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Pelican Technical Article:

Fuel Pump Replacement

Jared Fenton

Time:

2 hours2 hrs

Tab:

$200

Talent:

***

Tools:

Phillips head screwdriver, hammer and drift, small screwdriver

Applicable Models:

Mercedes-Benz C250 (2012-14)
Mercedes-Benz C300 (2008-14)
Mercedes-Benz C350 (2008-14)

Parts Required:

Fuel pump assembly

Hot Tip:

Safety first! Disconnect battery, have a fire extinguisher nearby

Performance Gain:

Car runs again

Complementary Modification:

Change fuel filter

The fuel pump on the Mk4 Jetta is one of those items that will "not if, but when it fails". The design of the fuel tank in the Mk4 Jetta allows you to replace the fuel pump through an access hole below the rear seats. In this article I'll go over the steps involved with changing it out.

Keep in mind that we will be working around raw fuel. Have a fire extinguisher nearby and obviously keep any flames or sources of ignition well away from the car. Additionally, open all the doors and rear hatch and make sure the area in which you work is well ventilated. Fuel vapors can be very dangerous. I also recommend wearing fuel resistant gloves and a carbon filter mask to protect you.

You'll want to have the fuel level in the car as low as possible before starting this job. Wait until the car's fuel level is on reserve before opening up the fuel tank. If the fuel pump is completely dead, you'll want to use a small pump and hose to get as much fuel out as you can. The fuel pump housings themselves can hold quite a bit of fuel. As you pull them up out of the fuel tank, it can be difficult to prevent spilling fuel everywhere. Subsequently, it's a good idea to have plastic sheeting on hand to cover the carpeting.

You'll also need to relieve the pressure in the fuel system prior to removing the fuel lines. Failure to do so can result in pressurized fuel shooting out of the lines when they are disconnected. Removing the fuses for the fuel pump and running the car until it dies relieves the fuel pressure. See our article on Fuel Pressure Regulator Replacement for more information. It is also a wise idea to disconnect the battery. See our article on Battery Replacement for more information.

The fuel pump is accessed from under the rear seats.
Figure 1

The fuel pump is accessed from under the rear seats. Lift the right side lower seat cushion up. You'll see a flap cut into the carpet (green arrow).

Lift the flap up and over as shown here.
Figure 2

Lift the flap up and over as shown here. Then loosen and remove the three Phillips head screws (green arrows) holding the cover plate to the floor. Pry the cover plate up and off the floor.

Shown here is the fuel pump mounted in the fuel tank through the access hole.
Figure 3

Shown here is the fuel pump mounted in the fuel tank through the access hole. Use a small screwdriver to press the tab on the electrical connector (green arrow) and pull it off the fuel pump.

This picture shows the fuel line connections that lead to the engine.
Figure 4

This picture shows the fuel line connections that lead to the engine. Note the color differences for when you re-attach the lines to the new tank. Press the small tabs (green arrows) on the fuel line connectors and pull them up and off the pump. Use caution not to damage the plastic fuel lines.

Tuck the fuel line connectors out of the way as best you can (green arrow).
Figure 5

Tuck the fuel line connectors out of the way as best you can (green arrow). You'll now need to remove the locking ring holding the pump in the fuel tank. VW sells a special tool for this but I've found that the appropriate sized drift along with a hammer will work as well. Place the drift on the backside of the ribs (yellow arrow) and hit the drift in a counter-clockwise direction. It will take a while, but you can get it off.

Note the orientation marks (green arrows).
Figure 6

Note the orientation marks (green arrows). When installing the new pump, these marks must be aligned.

Pull the old pump up out of the fuel tank.
Figure 7

Pull the old pump up out of the fuel tank. You'll have to maneuver it around a bit to slide it upward. It is very helpful to have plastic sheeting around the edges of the access hole to prevent raw fuel from spilling onto the carpet. Also note the seal (green arrow). You'll want to replace this with the new pump.

Now slowly pull the pump up and allow the fuel inside to drain back into the tank.
Figure 8

Now slowly pull the pump up and allow the fuel inside to drain back into the tank. Note the fuel level in the pump (green arrow). Once drained, pull the pump out. The new pump installs in the reverse order of removal. Take note to install the new seal on the lip of the fuel tank first. Then slide the pump inside.

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Comments and Suggestions:
Cochise Comments: Too late. Already purchased the part.
October 1, 2016
  Followup from the Pelican Staff: OK. - Nick at Pelican Parts  
Cochise Comments: I would like to purchase a fuel pump assembly for a 2003 VW Jetta GLI with a 2.8L engine. The technical article shows a Mercedes-Benz and the car they describe in the article is a Mk4 Jetta. Not too comfortable with all this.
Question: Will Part #: 1J0-919-087-JMY-INT fit my car?
September 29, 2016
  Followup from the Pelican Staff: I’m not the best with part numbers.

Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 

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