Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

Removing

Observe safety precautions. Refer to => [ Fuel System ] Fuel System.

Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.

• The fuel tank may only be maximum 3/4 full when removing the fuel delivery unit. Empty fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Procedures.

- Remove rear seat bench.






- Unclip the retainers - arrows - of the cover for sealing flange.

- Disconnect electrical harness connector - arrow - at locking flange.







• Fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.

• The temperature of the fuel lines or fuel may reach 100 °C (212 °F) after stopping the engine. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.

• Wear protective gloves.

• Wear safety glasses.

- Press the release buttons and disconnect the fuel supply line - 1 - and the fuel return line - 2 -.







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 with (T10202).






- Remove the fuel delivery unit and the seal through the opening in the fuel tank.

• When removing fuel delivery unit, be sure not to bend floater arm on the fuel level sensor (G).

• Be sure there is still some fuel inside the fuel delivery unit.

Installing

• Tightening specifications, refer to => [ Fuel Delivery Unit and Fuel Level Sensor Assembly Overview ] Fuel Delivery Unit and Fuel Level Sensor Assembly Overview.

Installation is in the reverse order of removal, note the following:

• Do not bend the fuel level sensor when inserting the fuel delivery unit.

• Ensure fuel hoses are seated securely.

- Install the fuel delivery unit into the fuel tank.






- Install the new locking flange seal dry.

- Press the locking flange down and bring it into the installation position.

• The tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

• - Arrow - points in direction of travel.

- Tighten locking ring.






- After installing fuel delivery unit, fill vehicle with at least 5 liters of fuel.