Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

Removing

- Follow all safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.

- Follow the guidelines for clean working conditions. Refer to => [ Clean Working Conditions ] Fuel Supply System.

Danger due to escaping fuel.

• To prevent large quantities of fuel from leaking from the fuel delivery unit when removing, the fuel tank may only be a maximum of 1/4 full.

- Empty the fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Procedures.

- Move the right front seat all the way forward.






Danger of causing damage to other electronic components when disconnecting the battery.

• Complete the steps for disconnecting the battery.

- Disconnect the Ground (GND) cable - 2 - from the battery.

- Remove the rear bench seat.

- Fold the insulation mat near the locking flange cover to the side.

- Remove the bolts - arrows - and the locking flange cover.






- Disconnect the connectors - 1 and 2 - on the locking flange.











There is a risk of injury because the fuel is under high pressure.

• To reduce pressure in the fuel system, lay a clean cloth around the connector and carefully loosen connector.

- Remove the fuel line - 2 - from the locking flange.

- Press the connecting piece - 1 - all the way - arrow A - and hold it pressed.






- Press the release buttons - 2 - - arrows B - and remove the connecting piece.








Danger due to escaping fuel.

• To prevent large quantities of fuel from leaking from the fuel delivery unit when removing, the fuel tank may only be a maximum of 1/4 full.

- Remove the locking ring using the (T10202).

- Pull the locking flange - 1 - just a little out of the opening in the fuel tank and remove the seal.






- Disconnect the connector - 2 -.

- Carefully remove the locking flange and fuel filter together with the fuel lines through the opening in the fuel tank.








There is a risk of fuel leaking out from the filled fuel delivery unit.

• Lay cloths below to catch the leaking fuel.

- Carefully remove the fuel delivery unit - 2 - and fuel level sensor - 1 - 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).

Separate the Fuel Delivery Unit and Locking Flange






- Cut the plastic seal - arrow -.

• The seal is used only as an assembly aid and does not have to be installed again.

- Disconnect the connectors - 2 and 3 -.






- Press the release button and disconnect the fuel supply line - 1 - from the fuel pressure regulator.

- Remove the locking flange from the fuel delivery unit.

Installing

Install in reverse order of removal. Note the following:

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

• Replace the seal.

• Make sure the fuel hoses are secure.

• When inserting the fuel delivery unit, do not bend the floater arm on the fuel level sensor.

- Route the GND cable as illustrated.






1. Locking Flange

2. GND cable to locking flange

3. Fuel pressure regulator

4. GND cable to fuel pressure regulator


Make sure the fuel supply hose is installed correctly:






• The fuel supply hose must be installed on the outside around the guide tubes.

- Install the guide tubes - 3 and 6 - with the pressure spring - 5 - from the locking flange - 4 - into the guide on the fuel delivery unit - 1 -.

- Guide the fuel level sensor 2 (G169) wire out of the fuel tank.






- Carefully install the fuel delivery unit and fuel level sensor back into the fuel tank.

- Make sure the fuel level sensor 2 wire is installed correctly:

• Guide the fuel level sensor 2 wire - 5 - between the guide tubes - 2 and 3 - and the fuel pressure regulator - 4 -.

• Guide the wire - 5 - over the supply hose - 1 - and behind the wires - 6 - for the fuel level sensor and - 7 - transfer fuel pump.

- Connect the connector - 2 - for fuel level sensor 2 to the locking flange - 1 - and make sure it is locked secure.






- Carefully guide the transfer fuel pump (G6) fuel supply line leading to the fuel pressure regulator into the fuel tank.

Verification






• The locking flange guide pipes - 2 and 3 - must be inserted into the guides on the fuel delivery unit.

- Install the new locking flange seal - 4 -. The seal must dry.






Risk of leaking.

• When inserting sealing flange, sealing ring must not be damaged or crushed.

- Press the locking flange downward against the spring force and move it into its installed position.

• The tab - 1 - on the locking flange must face the hole - arrow - in the fastener and between the tabs - 2 and 3 - on the fuel tank.

- Attach the fuel lines so that they audibly latch.

- Connect the connectors and make sure they are secure.

- Install the right locking flange cover. Refer to => [ Locking Flange Cover - Tightening Specifications ] Fuel Delivery Unit and Fuel Level Sensor Overview.

- Install the rear bench seat.

- Connect the battery. Be sure to read the procedures after connecting the battery.

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