Fuel Delivery Unit
Fuel Delivery Unit
Special tools, testers and auxiliary items required
• Wrench (T10202)
Removing
Follow all Safety Precautions. Refer to => [ Safety Precautions ] General Information.
Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
Risk of destroying electronic components when disconnecting the battery.
• Observe measures for disconnecting battery.
- Disconnect the battery.
Danger of fuel entering vehicle interior.
• The fuel tank must be empty in order to remove the fuel delivery unit.
- Empty fuel tank. Refer to => [ Fuel Tank, Draining ] Procedures.
- Remove 2nd row left seat cushion.
Risk of injury.
• Wear safety gloves.
- Cut the floor covering along the perforation - arrows - on the left side with a carpet knife - 1 -.
- Fold the floor covering to the side - arrow -.
- Remove nuts - 1 to 4 - and remove left locking flange cover.
- Disconnect electrical harness connector - 1 - at left locking flange.
- Disconnect the vent line - 2 - by pressing release button.
- Remove locking ring with (T10202).
- Pull left locking flange with fuel filter housing and gasket out of the fuel tank slightly.
- Disconnect electrical connector on inner side of locking flange - arrow -.
- Disconnect fuel lines - 1 and 2 - from the left locking flange by pressing the release button.
- Remove right seat frame in 2nd row.
Risk of injury.
• Wear safety gloves.
- Cut the floor covering along the perforation - arrows - on the right side with a carpet knife - 1 -.
- Fold the floor covering to the side - arrow -.
- Remove nuts - 1 to 4 - and remove right locking flange cover.
- Disconnect electrical harness connector - 3 - at right locking flange.
Risk of injury from fuel.
• To reduce residual pressure remaining in fuel system, lay a clean cloth around the connector and carefully loosen connector.
- Disconnect the fuel supply line - 2 - from right locking flange.
- Remove locking ring using (T10202).
- Pull right locking flange with seal out of fuel tank a bit.
- Disconnect electrical connectors - 1 and 2 - on the underside of the right locking flange.
- Disconnect the fuel line - arrow - by pressing the release button.
- Grasp in fuel tank opening and remove fuel delivery lines - 1 and 4 - by pressing releases.
- Disconnect the suction jet pipe - 2 - to suction jet pump by pressing release button.
- Remove fuel lines - 3 - from opening on the right of the fuel tank.
- Reach into the opening in the fuel tank and release the fuel delivery unit - 1 - by turning it counter-clockwise 15° - arrow - (bayonet connection).
• The fuel delivery unit is illustrated without the fuel tank.
• The notch - 3 - on the fuel delivery unit then aligns with the retaining ring tab - 4 -.
- Remove the fuel delivery unit.
• Be sure there is still some fuel inside the fuel delivery unit.
Installing
• Tightening specification, refer to => [ Fuel Delivery Unit and Fuel Level Sensor (G) Overview ] Fuel Delivery Unit and Fuel Level Sensor (G) Overview.
Install in reverse order, paying attention to the following:
• Replace seals.
- Install the fuel delivery unit into the fuel tank.
• The notch - 3 - on the fuel delivery unit then aligns with the retaining ring tab - 4 -.
• It must be possible to push the fuel delivery unit downward.
- Lock the fuel delivery unit - 1 - into place by turning it clockwise 15° (bayonet connection).
- Slide the fuel lines - 3 - through opening at right of fuel tank to left fuel tank chamber.
- Push the suction jet pipe - 2 - onto the suction jet pump until it engages audibly.
- Attach the delivery lines - 1 and 4 - to the fuel delivery unit making sure they click into the place.
- Attach the fuel line - arrow - until it engages audibly.
- Connect electrical connectors - 1 and 2 - on the underside of the right locking flange.
- Install new locking flange seal dry.
- Bring the right locking flange into the installation position.
• Tab - 2 - on the right locking flange faces toward arrow marking and must lie between tabs - 1 and 3 - on the fuel tank.
- Attach fuel lines - 1 and 2 - on left locking flange until they audibly engage.
- Connect electrical connector - arrow - on the underside of the left locking flange.
- Install new locking flange seal dry.
- Bring the left locking flange into the installation position.
• The tab - 2 - on left locking flange faces toward the arrow marking and must lie between tabs - 1 and 3 - on the fuel tank.
- Install locking flange cover.
- Install the frame into the floor covering. and to the Electronic Parts Catalog (ETKA)
- Remove seat frame and seat cushion in 2nd seating row.
- Be sure to follow the procedure for connecting the battery and afterwards.
- After installing fuel delivery unit, fill vehicle with at least 5 liters of fuel.