Fuel Delivery Unit, Removing and Installing

Fuel Delivery Unit, FWD, Removing And Installing

Observe safety precautions.
Observe rules for cleanliness.

Recommended Special Tools, Workshop Equipment, Testers, Measuring Instruments and Auxiliary Items
- 3217 ring nut spanner

Removing
- Note and if necessary obtain radio code (for vehicles equipped with coded anti-theft radio).







- If available, remove cover over battery - arrows -.
- Open battery protective casing (Velcro).







- Disconnect battery Ground (GND) strap - arrow - with the ignition switched off.

CAUTION: To remove fuel delivery unit, fuel tank may only be filled to a maximum of 1/3.

- Empty fuel tank if necessary.
- Remove rear seat bench.
- Remove right cover under rear seat bench.







- Carefully release and disconnect 4-pin electrical connection - arrow -.

CAUTION: 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 fuel return line - 2 - (press release button).







- Remove union nut using ring nut spanner - 3217 -.
- Pull fuel delivery unit and seal out of the opening in fuel tank.

NOTE: If delivery unit is still filled with fuel, empty before replacing.

Installing

Installation is performed in the reverse order of removal, noting the following:

NOTE:
- Insert new, dry seal for locking flange into opening of fuel tank.
- When inserting fuel delivery unit, be sure not to bend fuel level sensor floater arm.
- Ensure fuel hoses are seated securely.







- Press locking flange down against spring pressure and bring it into installation position.
- Marking on locking flange must align with marking on fuel tank -arrows-.

- Tighten union nut by hand.







- Tighten union nut using ring nut spanner - 3217 - (80 Nm ).







- Connect fuel lines.
- Black supply line -1 - to connection with designation - V -.
- Blue return line - 2 - to connection with designation - R -.

- Connect electrical 4-pin connector.
- After connecting battery, enter radio anti-theft code. See Radio operating instructions.
- Raise windows with electric window regulators up to stop.
- Then activate all power window switches ("up") for at least one second to activate automatic window raising/lowering.
- Set clock.
- Erase DTC memory of ECM.
- Generate readiness code.

Tightening torque

Component Nm
Fuel delivery unit union nut 80 Nm
Battery clamp to battery terminal 5 Nm