Fuel Delivery Module, Removing and Installing

Observe safety precautions.
Observe rules for cleanliness

Special tools and workshop equipment required







- 2012 A wrench







- 3342 ring nut spanner


CAUTION!
- A leak test must be performed after reinstalling the fuel delivery module %, refer to "Leak Checking"Testing and Inspection This is necessary to ensure that the baffle housing (integrated reservoir) is not leaking.
- If the baffle housing is not fuel-tight the engine will cut out due to fuel starvation when the tank is still 1/3 to 1/4 full.
- The chambers of the fuel tank must be completely emptied before performing the leak test.
- It is advisable to remove the spare wheel and tool kit from the trunk before removing and installing the fuel delivery module. It is then possible to sit or kneel in the spare wheel well, which makes it easier to feel whether the fuel delivery module is located properly when guiding it in.


Removing
- Obtain radio code on vehicles with coded radio/integrated radio and navigation system.
- With ignition switched off, disconnect battery Ground (GND) cable.
- Remove cover for fuel level sender and fuel delivery module under carpet in trunk (right side).







- Using 2012 A special tool , release flange for fuel level sender by turning it clockwise, detach flange and remove spring below it.







- Using pliers, carefully lift fuel level sender slightly and disconnect connector -arrow-.


CAUTION!
- If the top cover on the sensor should come loose when pulling it out, the housing of the sensor must be removed separately.
- If the sensor has come apart, replace the complete sensor.


- Secure harness connector to prevent it dropping back into fuel tank.
- Pull out fuel level sender completely.
- Extract remaining fuel in right-hand chamber through opening for fuel level sender.
- Remove Sender -2- for fuel gauge -G169 (left side).
- Extract remaining fuel in left-hand chamber through opening for fuel level sender 2.







- Disconnect harness connector -1-.


WARNING!
- Fire hazard. DO NOT smoke or work near heaters of have anything in the area that can ignite fuel
- Fuel system is under pressure. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.


- Unscrew banjo bolt -2- for fuel supply pipe.
- Disconnect fuel return pipe -3-.







- Unscrew locking ring with special tool 3342.







- Unscrew securing bolt -1- several turns, but do not remove.
- Press securing bolt down firmly -arrow- to separate fuel delivery module from adapter plate in fuel tank.
- Unscrew securing bolt completely and pull out.
- Lift fuel delivery module slightly and pull off seal.
- Lift fuel delivery module out of fuel tank by simultaneously pulling upwards and turning clockwise.


WARNING!
If the delivery module is still full of fuel, empty it before replacing.


Installing
Installation is carried out in the reverse order, when doing this note the following:


WARNING!
Fire hazard. DO NOT smoke or work near heaters of have anything in the area that can ignite fuel.







- Before installing, check whether filler pipe -1- is clipped onto pipe retainer -arrow- on adapter plate -2-.


NOTE:
- The cut-away shows the fuel tank from the front.
- A flashlight and mirror can be used to check whether the filler pipe is clipped in properly.
- If the adapter plate and filler pipe are not clipped together it will not be possible to install the fuel delivery module properly, and the adapter plate can be damaged when installing.


- Before inserting fuel delivery module, visually inspect baffle housing, lower section of baffle housing, and pipe connections for suction jet pumps.
- Replace O-ring (item 4) and sealing plug (item 3) Fuel Delivery Module and Fuel Level Senders, Remove/Install
- Secure electrical connector for fuel level sender onto flange at top so that it does not drop into the tank during installation.
- Install fuel delivery module as follows:







- Starting position: hose connection on top of flange pointing towards left side of vehicle (position 1)
- Insert fuel delivery module into opening in fuel tank.
- While inserting, rotate fuel delivery module about 180° counter-clockwise about its own axis -arrow-.
- Hose connection on top of flange then points towards right side of vehicle (position 2)
- The arrow markings -2- and -3- should line up.







- Hold fuel delivery module in this position about 40 mm above opening in the fuel tank, as illustrated.


NOTE: The cut-away shows the fuel tank from the front.


- Press fuel delivery module downwards.
- The output pipe (motion stream) from the fuel delivery module to the suction jet pumps will then be pressed down into the funnel on the adapter plate -arrows-.


CAUTION!
- If the output pipe (motion stream) from the fuel delivery module to the suction jet pumps is not pressed down into the funnel on the adapter plate, the suction jet pumps will not work and the fuel delivery module will not seal against the adapter plate
- If the baffle housing in not fuel-tight or the suction let pumps are not working, the engine will cut out due to fuel starvation when the fuel tank is still 1/3 to 1/4 full.


It is not possible to see from the outside whether the components have been assembled properly, so check as follows before finally securing in place.
- The flange of the fuel delivery module should fit flat and square on the opening in the fuel tank.
- The securing bolt should slip easily and without obstruction into the thread in the adapter plate, and should screw in easily and smoothly.

- After checking the installation, lift out the fuel delivery module slightly and install the flange seal in the rim of the opening on the fuel tank.
- Insert fuel delivery module again.







- Install new O-ring -1- on securing bolt -2-.
- Tighten securing bolt finger-tight (to start with).







- Install locking ring and tighten to 90 Nm using special tool 3342.
- Tighten securing bolt to 23 Nm.







- Tighten banjo bolt -2- for fuel supply line to 23 Nm.
- Connect fuel return hose -3- and secure with new hose clamp.
- Connect harness connector -1-.
- Replace O-ring on fuel level sender (item 4) and sealing plug (item 3) Fuel Delivery Module and Fuel Level Senders, Remove/Install
- Insert fuel level sender.







- Reconnect electrical connector -arrow- when sliding fuel level sender back into tank.
- Install pressure spring.







- Using special tool 2012 A, carefully tighten flange for fuel level sender by turning it counter-clockwise as far as it will go.
- Connect battery and enter anti-theft code on vehicles with coded radio/radio and navigation system

See Radio operating instructions

- Close windows fully to top using electric window switches.
- Then operate all electric window switches again for at least one second in the "Close" position to activate the automatic up and down function.
- Set clock to correct time.
- Check fuel delivery module for leaks, refer to "Leak Checking" Testing and Inspection