Section J - Fuel Sending Unit Installation

(2001-2005 4Motion vehicles)





- Insert fuel pump into baffle housing of new fuel tank so that notch -1- at fuel delivery unit aligns with marking -2- at the baffle housing

- In this position, fuel pump can be pressed downward noticeably





- Turn fuel pump approximately 15� toward right until impact using fuel pump wrench -3307-





- Notch -1- aligns with marking -3- (bayonet connection)





- Press on return line -1- on distributor piece -4- until hose coupling engages

NOTE:
Always use new O-rings -9- for fuel return line
Coat O-rings for fuel return line with fuel





- Connect distributor piece -4- to baffle housing -8- and ensure distributor piece is fully seated





- Reattach connectors -1- and -2- to inside of flange

- Install new seal for flange onto opening of fuel tank and coat inside with fuel





- Insert lines into fuel tank and install flange
- Marking on flange -1- must align with marking on fuel tank -2-
- Check sealing ring for correct position
- Tighten locking ring using special wrench for tank sensor -3087-
- Reinstall removed parts in reverse order, using new sub-frame bolts
- Align sub-frame to vehicle, using marks made prior to sub-frame removal
- Perform rear alignment
- Check parking brake cable adjustment; adjust if necessary
- Set basic settings
- Reset clock, radio station pre-sets and window "one-touch" feature
- Ensure proper function of remote control key; adapt key if necessary

NOTE:
Inform customer that additional remote control key(s) may need to be adapted to work properly

- Set basic settings
- Destroy and properly discard all removed parts
- 1.8T 4Motion automatic transmission vehicles proceed to Section K
- 2.8L & W8 4Motion automatic transmission vehicle

Work is Complete