Fuel Delivery Unit, Removing and Installing

Fuel Delivery Unit, Removing And Installing

Special tools, testers and auxiliary items required







- Wrench 3087

Removing

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 Electrical Equipment -.







- 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 the right rear seat backrest of, if necessary.

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







All models:
- Unbolt cover for locking flange in luggage compartment - arrows -.







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







- Mark fuel supply line -1- and fuel return line -3-.

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.
- Disconnect ventilation line -2- by pressing release buttons.

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 locking ring using wrench 3087.
- Lift fuel delivery unit slightly out of the fuel tank opening and remove seal.







- If fuel delivery unit is still inserted in fuel tank, slide fuel delivery unit with locking flange slightly to the side.
- Reach through the 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.







- Pull suction jet pump -1- upward with suction jet pipe -2- still connected.
- Disconnect suction jet pipe 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.

Instaling
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 pipe -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.

- 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.







- Install fuel supply line -1- and fuel return line -3- according to the marking.
- Install ventilation line -2-.
- Connect electrical harness connector.
- Connect battery. Observe safety precautions after connecting battery Electrical Equipment -.

Torque specifications

Component Nm
Locking ring for fuel delivery unit 145