Vehicle With Front Wheel Drive

Fuel Delivery Unit, Removing And Installing

Special tools and equipment







- Union nut wrench 3087
- The fuel tank must not be more than 3/4 full when removing the fuel delivery unit. Drain fuel tank if necessary.


WARNING: Observe safety precautions when disconnecting the battery.


- With ignition switched off, disconnect battery ground strap.

Sedan:
- Detach trim in luggage compartment.
- Fold down rear right seat backrest if necessary.

Avant:
- Remove 1/3 backrest, left.
- Remove left side trim of luggage compartment and protective pan.

All models:







- Detach cover for flange -arrows-.







- Disengage and remove electrical harness connector -1-.
- 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.







- Mark fuel supply pipe -1- and fuel return pipe -3- and disconnect (press release tab).
- Disconnect breather pipe -2- (press release tab).


WARNING: The fuel tank must not be more than 3/4 full when removing the fuel delivery unit.







- Unscrew locking ring using wrench 3087.
- Carefully pull fuel delivery unit a short distance out of fuel tank opening together with seal.
- Move flange slightly to one side with fuel delivery unit still located in fuel tank.







- Reach into gap between flange and opening in fuel tank and release suction jet pump -1-.


NOTE: The fuel tank is shown in partial section.







- Lift suction jet pump -1- with suction jet pipe -2- connected.
- Disconnect suction jet pipe from suction jet pump (press release tab).
- Remove suction jet pump.
- Take out fuel delivery unit.

Installing
Install in reverse sequence; note the following points:







- Attach suction jet pipe -2- to suction jet pump connection -1-.
- Fit fuel delivery unit in fuel tank.







- Clip suction jet pump -1- onto fuel delivery unit. To do this reach into gap between flange and opening in fuel tank.
- The suction jet pump should engage with an audible click.

- Fit new seal for flange in fuel tank opening (seal should be dry).







- Note installation position of fuel delivery unit:
- Lug -2- at flange must be positioned between tabs -1- and -3- at fuel tank.


NOTE: The arrow points in the direction of travel.







- Tighten locking ring on flange to 145 Nm.







- Install fuel supply pipe -1- and fuel return pipe -3- (as marked on removal).
- Install breather pipe -2-.
- Connect electrical harness connectors.
- Observe safety precautions after connecting the battery.

Tightening torques

Component Nm
Union nut for fuel delivery unit 145
Battery terminal to terminal post 6