Vehicles with All Wheel Drive

Fuel delivery unit, removing and installing
(Vehicles with all wheel drive up to 06.03)

Special tools, testers and auxiliary items required




- Wrench T10202




- Fuel pump wrench 3307

REMOVING

- Observe safety precautions.
- Observe rules for cleanliness.

CAUTION!
- To remove the fuel delivery unit, the fuel tank may only be filled to a maximum of 1/4. Drain fuel tank if necessary.
- Observe procedures for disconnecting battery.






- Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 - .






- With ignition switched off, disconnect Battery Ground (GND) strap - arrow - .
- Open fuel filler flap briefly and then close again.






- Remove rear seat bench.
- Unbolt cover for right locking flange - arrows - .






- Disconnect electrical harness connector - 1 - at right locking flange.
- Disengage electrical harness connector - 2 - and lay it aside.

CAUTION!
- The fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.






- Disconnect fuel line - 1 - from locking flange by pressing release button.

Vehicles with 1.8L Turbo engine:
- Disconnect ventilation line - 2 - to fuel filter at locking flange, by pressing the release buttons.

All models:

CAUTION!
- The fuel delivery unit may only be removed when fuel tank is maximum 1/4 filled. Otherwise, a large amount of fuel will spill out.






- Remove locking ring using wrench T10202 .
- Pull locking flange and sealing ring from opening of fuel tank.






- Disconnect electrical connection on inner side of locking flange - arrow - .






Note: To improve clarity, a cross-sectional view of the fuel tank is shown in the following illustration.

- Guide fuel pump wrench 3307 through the fuel tank opening and place it on the fuel delivery unit.
- Release fuel delivery unit with fuel pump wrench 3307 , thereby turning approx. 15� toward left until stop (bayonet connection).






- Notch - 1 - aligns with marking - 2 - .
- Remove fuel delivery unit.

Note: Be aware that fuel is still in the fuel delivery unit.

INSTALLING

- Installation is in reverse order of removal. Note the following:

Note: Replace seal.






- Insert fuel delivery unit into baffle housing in tank so that the notch - 1 - at fuel delivery unit aligns with marking - 2 - at baffle housing.
- Fuel delivery unit can be pressed downward significantly and noticeably.






- Guide fuel pump wrench 3307 through fuel tank opening and place it on fuel delivery unit.






- Fasten fuel delivery unit using fuel pump wrench 3307 , thereby turning approx. 15� toward right until stop (bayonet connection).
- Notch - 1 - aligns with marking - 3 - .






- Connect electrical connection - arrow - on inner side of locking flange.
- Install new locking flange seal dry.
- Bring locking flange to installation position.






- Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

Note: - Arrow - points in direction of travel.






- Tighten locking ring.
- Connect battery. Observe safety precautions after connecting battery.

Torque specifications
Locking ring for fuel delivery unit 145 Nm