Vehicles with Front Wheel Drive

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

Special tools, testers and auxiliary items required




Ring nut wrench 3217

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 3/4. 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 - .

Sedan:
- Remove carpeting in luggage compartment.
- Fold forward right rear seat backrest, if necessary.

Wagon:
- Remove left 1/3 backrest.
- Remove left side luggage compartment trim and dirt tray.

All models:






- Unbolt locking flange cover in luggage compartment - arrows - .






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






- Mark fuel supply line - 1 - and fuel return line - 2 - .

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

- Pull both lines from locking flange, by pressing release buttons.

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

All models:

CAUTION!
Fuel delivery unit may only be removed when fuel tank is maximum 3/4 filled. Otherwise, a large amount of fuel will spill out.






- Remove union nut using Ring nut wrench 3217 .






- Lift fuel delivery unit slightly out of fuel tank opening and remove seal.
- If fuel delivery unit is still inserted in fuel tank, slide locking flange slightly to side.
- Reach through gap between locking flange and installation opening in fuel tank and release suction jet pump - 1 - .

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






- Lift suction jet pump - 1 - upward with suction jet pipe - 2 - still connected.
- Disconnect suction jet line from suction jet pump by pressing release button.
- Remove suction jet pump.
- Remove fuel delivery unit.

Note:
- When removing fuel delivery unit, be sure not to bend floater arm of Fuel Level Sensor G .
- 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.
- When installing fuel delivery unit, be sure not to bend floater arm of fuel level sensor G .
- Make sure fuel hose is seated securely.

- Insert fuel delivery unit into fuel tank.






- Connect suction jet line - 2 - to connection for suction jet pump - 1 - .






- Clip in suction jet pump - 1 - on fuel delivery unit. To do so, insert hand into gap between locking flange and installation opening of fuel tank.
- Suction jet pump must engage audibly.
- Verify that the suction jet pump is securely engaged.

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






- Install new locking flange seal dry.
- Press locking flange down against spring pressure and bring it into installation position.
- Marking - 2 - on locking flange must align with marking - 1 - on fuel tank.






- Tighten union nut for locking flange.






- Install fuel supply line - 1 - and fuel return line - 2 - according to marking.

Vehicles with 1.8L Turbo engine:
- Also, install ventilation line to fuel filter at locking flange.

All models:
- Connect electrical harness connector.
- Connect battery. Observe safety precautions after connecting battery Electrical Equipment.

Torque specifications
Union nut for fuel delivery unit 80 Nm