Left Fuel Delivery Unit with Transfer Fuel Pump

MPI Engines

Left Fuel Delivery Unit with Transfer Fuel Pump

Special tools, testers and auxiliary items required

• Wrench (T10202)

Removing

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

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


• To remove the fuel delivery unit, the fuel tank may only be filled to a maximum of 1/3. Empty fuel tank if necessary. Refer to=> [ Fuel Tank, Draining ] Procedures.


Observe measures when connecting battery.

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





- Remove the luggage compartment floor mat.

• To remove and install fuel delivery unit, remove vehicle tool kit and spare wheel from luggage compartment. It is then possible to sit or kneel in spare wheel well.

- Unbolt cover for left locking flange - arrows -.





- Disconnect electrical connectors - 1 - and - 2 - at left locking flange.





- Remove locking ring with Wrench (T10202).





- Pull off locking flange and remove the seal.





- Separate the electrical connectors - 1 to 3 - on the underside of the left locking flange.

- Unbolt cover for right locking flange - arrows -.





- Disconnect electrical connectors - 1 - and - 2 - at right locking flange.





- Mark the fuel return line - 1 - and fuel supply line - 2 -.






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

- Pull both lines from locking flange, by pressing the release buttons.

- Remove locking ring with Wrench (T10202).





- Pull off locking flange and remove the seal.





- Separate the electrical connectors - 1 to 3 - on the underside of the right locking flange.

• To separate the line couplings that are mentioned later in the description, pull the fuel lines out of the fuel tank opening.

• To improve clarity, the following illustration shows several components not installed.

- Through the right fuel tank opening, separate the fuel lines - 1 - and - 2 - for the left fuel delivery unit by pressing the release buttons.





3 Right fuel delivery unit with Fuel Pump (FP) (G23)

- After separating both fuel lines, pull it out of the left fuel tank opening.

- Through the left fuel tank opening, press the release buttons - arrows - and remove the fuel delivery line - 2 - and the Fuel Level Sensor 3 (G237) - 1 -.





- Swing Fuel Level Sensor 3 (G237) aside to left.

- Press down both retaining clasps on the fuel delivery unit support - arrows -.





- Remove fuel delivery unit.

• Be aware that fuel is still in the fuel delivery unit.

Installing

• Tightening specifications. Refer to => [ Left Fuel Delivery Unit with Transfer Fuel Pump and Fuel Gauge Assembly Overview ] MPI Engines Overview.

- Before installing the fuel delivery unit, pull the retaining clasps on the support upward until it engages - arrows -.





- Carefully press the fuel delivery unit into the support until it engages audibly.

- Insert the fuel delivery line - 2 - and the Fuel Level Sensor 3 (G237) - 1 - until it engages audibly.





- Feed the supply and return lines of the left fuel delivery unit through toward the right chamber of the fuel tank.

- Through the right fuel tank opening, press the fuel lines - 1 - and - 2 - on until they engage audibly.





3 Right fuel delivery unit with Fuel Pump (FP) (G23)

- Connect the electrical connectors - 1 to 3 - on the underside of the right locking flange.





- Install the new locking flange seal dry.

- Insert locking flange in fuel tank, note installation position:





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

- Tighten locking ring.





- Install fuel supply line - 2 - and fuel return line - 1 - according to marking until they engage audibly.





- Connect electrical harness connectors - 1 - and - 2 - to right locking flange.





- Fasten the cover for right locking flange - arrows -.





- Connect the electrical connectors - 1 to 3 - on the underside of the left locking flange.





- Install the new locking flange seal dry.

- Insert locking flange in fuel tank, note installation position:





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

- Tighten locking ring.





- Connect electrical harness connectors - 1 - and - 2 - to left locking flange.





- Fasten the cover for left locking flange - arrows -.





- Connect battery. Observe safety precautions after connecting battery.

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