Fuel Pump (FP) and Fuel Level Sensor -G-, Assembly Overview

Fuel Pump (FP) And Fuel Level Sensor -G-, Assembly Overview







Part I

1 - Fuel Level Sensor -G-
- Clipped in at baffle housing in fuel tank
2 - Fuel pump
- Various versions, allocation
- Can only be replaced complete with connector flange
- Check Fuel Pump (FP) electrically
- Checking fuel delivery: vehicles as of 07.03
- Checking residual pressure, vehicles up to 06.03, vehicles as of 07.03
3 - Electrical harness connector
- For Fuel Pump (FP) and Fuel Level Sensor -G-
- Releasing
4 - Connector flange
- For Fuel Pump (FP)
- Not individually replaceable
- Installation position
5 - Ventilation line
- Only in vehicles as of 07.03
- From fuel pressure regulator in fuel filter
- To disconnect, press release button on connection piece
- Do not bend
- Clipped in on fuel tank
6 - Seal
- To install, place into opening of fuel tank when dry
7 - Locking ring
- Use wrench 3087 to remove and install
- Tighten to 145 Nm
8 - Fuel supply line
- To fuel filter
- To disconnect, press release button on connection piece
- Do not bend
- Clipped in on fuel tank
9 - Distributor piece
- Various versions, allocation
- Clipped in on baffle housing with catches
- To remove, press toward right so that catches disengage and lift upward
10 - Fuel line
- To suction jet pump in baffle housing
11 - Fuel return line
- From connector flange, left side
12 - Fuel delivery line
- From suction jet pump, right side
13 - Baffle housing
- With suction jet pump







Part II

1 - Baffle housing
- With suction jet pump
2 - Distributor piece
- Various versions, allocation
- Clipped in on baffle housing with catches
- To remove, press toward right so that catches disengage and lift upward
3 - Fuel line
- To suction jet pump in baffle housing
4 - Fuel return line
- From connector flange, left side
5 - Fuel return line
- From engine / from fuel filter
- To disconnect, press release button on connection piece
- Do not bend
- Clipped in on fuel tank
6 - Seal
- To install, place into opening of fuel tank when dry
7 - Locking ring
- Use wrench 3087 to remove and install
- Tighten to 145 Nm
8 - Electrical harness connector
- For Fuel Level Sensor 2 -G169-
- Releasing
9 - Connector flange
- Only available together with
10 - Fuel Level Sensor 2 -G169-
- Only available together with
11 - Vacuum booster
- With lines
- Various versions, allocation
- Secured on connector flange
12 - Fuel delivery line
- From suction jet pump, right side







Fig. 1 Releasing harness connector
- To disconnect the multi-pin harness connector at Fuel Pump (FP), the harness connector must be released. This can be done by hand or by using a small screwdriver (arrow).

Fuel pump, removing and installing

CAUTION: To remove the Fuel Pump (FP), the fuel tank may only be filled to a maximum of 1/4. Empty fuel tank if necessary.

Recommended special tools and equipment







- 3087 wrench for tank sensor







- Fuel Pump Wrench 3307







- VAS5190 fuel siphoning device

Empty fuel tank

Observe safety precautions.
Observe rules for cleanliness.

CAUTION: For vehicles with Telematics, activate service mode of the control module before disconnecting the battery.

- Note and if necessary, determine radio code for vehicles equipped with coded anti-theft radio / radio navigation system only foreign brands).
- Switch ignition off.







- If installed, slide cover over battery to right (arrow -1-) and pull it off upward (arrow -2-)







- With ignition switched off, disconnect Battery Ground (GND) wire (arrow).

CAUTION: Secure Ground (GND) wire of VAS5190 to a blank portion of the chassis.







- Pull cone piece -2- from shaft piece -1- of VAS 5190.
- Using insulating tape, apply a mark (arrow) on hose at length a = 1865 mm from end of suction hose.
- Remove fuel filler cap from fuel filler tube.







- Screw shaft piece -1- of VAS 5190 fuel siphoning device on to fuel filler tube of fuel tank.
- Slide suction hose as far into fuel tank until the mark applied earlier (arrow) stands on shaft piece.

NOTE:
- If using a siphoning device without shaft piece, proceed principally in the same manner.







- In this case, apply a mark (arrow) on hose at length a = 1800 mm from end of suction hose using insulating tape. The suction hose is inserted correctly when the marking applied earlier stands opposite the lip of fuel filler tube.
- If the hose can only be inserted with difficulty, smear it thinly with engine oil. Never use lubricants containing silicon.

- Drain fuel tank through fuel filler tube as much as possible.
- Carefully remove siphoning hose.
- Remove rear seat bench.







- Remove cover for right connector flange (arrows).







- Carefully disengage and disconnect electrical harness connector -1- (right side of vehicle).
- Disengage electrical harness connector -2- and lay it aside.

WARNING: Fuel system is under pressure. Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.







- Disconnect fuel supply line -1- from connector flange (right side of vehicle).

Vehicles as of 07.03:
- Disconnect ventilation line -2- (press release button).

All:







- Use 3087 wrench to remove locking ring.
- Pull connector flange and sealing ring from opening of fuel tank.







- Disconnect harness connector (arrow) to fuel gauge on inside of connector flange.







- Slide suction hose for a length of dimension x = 800 mm through right opening on fuel tank to left tank chamber.
- Empty left fuel tank chamber.

Removing







- Disconnect harness connector (arrow) to fuel gauge on inside of connector flange.







- Guide fuel pump wrench 3307 in through fuel tank opening and position on Fuel Pump (FP).
- Rotate Fuel Pump (FP) toward left approx. 15 degrees to stop.







- Notch -1- aligns with marking -2- (bayonet connection)
- Remove Fuel Pump (FP).

Installing
Installation is in reverse of removal. Note the following:







- Insert Fuel Pump (FP) into baffle housing in tank so that the notch -1- at the Fuel Pump (FP) aligns with the marking -2- at the baffle housing.
- Fuel Pump (FP) can be pressed downward significantly and noticeably







- Guide fuel pump wrench 3307 in through fuel tank opening and position on Fuel Pump (FP).
- Rotate Fuel Pump (FP) toward right approx. 15 degrees to stop.







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







- Connect harness connector (arrow) for fuel gauge on inside of connector flange.
- Insert new, dry seal for connector flange into opening of fuel container.







- Note installation position of connector flange:
- Tab -2- on connector flange must lie between tabs -1- and -3- on fuel tank.

NOTE: Arrow points in direction of travel.







- Tighten locking ring.







- Install fuel supply line -1-.

Vehicles as of 07.03:
- Install ventilation line -2-.

Tightening torques
Locking ring for Fuel Pump (FP) 145 Nm
Battery terminal to battery post 6 Nm

Final procedures
After re-connecting the voltage supply, the following work steps must be performed in the mentioned sequence:
1. Check DTC memory. Diagnostic Mode 03 - Read DTC Memory
2. If necessary, erase DTC memory. Diagnostic Mode 04 - Erase DTC Memory
3. If DTC memory was erased, generate readiness code.

- End diagnostic.
- Activate vehicle equipment (radio/radio-navigation system, clock, electric window regulator), See Operating instructions
- Deactivate service mode of Telematics control module in vehicles with Telematics.
- Check radio-frequency remote control for function, synchronize radio-controlled key if necessary. Inform the customer that second and additional keys must also be synchronized to make sure radio-frequency remote control is functioning, See Operating instructions.