Vehicle With All Wheel Drive

Fuel Delivery Unit, Removing And Installing

Special tools and equipment







- Wrench for fuel tank sender unit 3087







- Fuel pump wrench 3307
- To remove the fuel delivery unit, the fuel tank must not be more than 1/4 full. Empty fuel tank if necessary.


WARNING: Observe safety precautions when disconnecting the battery.


- With ignition switched off disconnect battery ground strap.
- Open fuel filler cap briefly, then close it again.
- Remove rear seat bench.







- Detach cover for flange -arrows- (right side).







- Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
- Disconnect electrical harness connector -2- and set it aside.


WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.







- Disconnect fuel supply line -1- and breather pipe -2- from locking flange (right side of vehicle; press release button).


CAUTION: The locking flange must only be opened with the fuel tank not more than 1/4 full. Otherwise a great amount of fuel flows out.







- Remove locking ring using wrench for fuel tank sender unit 3087.
- Remove flange and seal out of opening in fuel tank.







- Disconnect connector -arrow- for fuel gauge sender on inside of flange.







- Insert fuel pump wrench 3307 through opening in fuel tank and apply wrench to fuel delivery unit.
- Turn fuel delivery unit counterclockwise as far as it will go (approx. 15 degrees).







- Notch -1- will then be aligned with marking -2- (bayonet fitting).

- Take out fuel delivery unit.

Installing
Install in reverse sequence; note the following points:







- Fit fuel delivery unit into baffle housing (in tank) so that notch -1- on fuel delivery unit is aligned with marking -2- on baffle housing.
- The fuel delivery unit should move down noticeably.







- Insert fuel pump wrench 3307 through opening in fuel tank and apply wrench to fuel delivery unit.
- Turn fuel delivery unit clockwise as far as it will go (approx. 15 degrees).







- Notch -1- will then be aligned with marking -3- (bayonet fitting).







- Connect electrical connector -arrow- for fuel gauge sender on inside of flange.
- Fit new seal for flange in fuel tank opening (seal should be dry).







- Note the installation position of connector valve:
- Lug -2- on flange must be between tabs -1- and -3- on fuel tank.


NOTE: Arrow points in direction of travel.







- Tighten locking ring (145 Nm).
- Observe safety precautions after connecting the battery.


Tightening torques

Component Nm
Locking ring for fuel delivery unit 145
Battery terminal to terminal post 6