Fuel Delivery Unit
Fuel Delivery Unit
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Wrench (T10202)
Removing
- Observe safety precautions. Refer to => [ Safety Precautions ] Safety Precautions.
- Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Slide the seats forward as far as possible. Then fold the backrest forward.
CAUTION!
Danger due to escaping fuel.
• To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of 1/ 4 full.
- Empty the fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
CAUTION!
Risk of destroying electrical components when battery is disconnected.
• Observe measures when disconnecting battery.
- With the ignition switched off, disconnect the battery ground (GND) cable - arrow -.
R8 Coupe
- Remove the rear shelf.
- Remove side trim panel.
- Remove the positive wire - 4 -.
- Disconnect the electrical connectors - 3 - on the connector station and remove the connector station from the control module bracket and lay it to the side.
- Remove the right rear relay and fuse carrier from the control module bracket and lay it aside - arrows -.
• Ignore - 1, 2 and 5 -.
- Disconnect the control module electrical connectors and remove the control module bracket - arrow - from the vehicle.
- Press the electrical wiring harness off the rear bulkhead using (80 - 200) and free it up.
R8 Spyder
- Remove the cover module.
All Vehicles
- Fold the insulation mat over the connection seal cover.
- Remove bolts - 1 through 4 - and remove the right locking flange cover.
- Disconnect the electrical connector - arrow - on the right locking flange.
CAUTION!
Risk of injury from fuel.
• To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.
- Disconnect the fuel lines - 1, 2, 3 - on the right locking flange by pressing the release buttons.
• Depending on the version, there may be 2 instead of 3 lines.
CAUTION!
Danger due to escaping fuel.
• To prevent large quantities of fuel from coming out of fuel delivery unit when removing, fuel tank may only be a maximum of 1/ 4 full.
- Empty the fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
- Disconnect the right locking flange locking rings using (T10202).
- Remove the fuel delivering unit locking flange and sealing ring from the opening in the fuel tank.
- Disconnect the fuel line - 1 - on the inside of the locking flange by pressing the release button.
- Disconnect the electrical connectors - 2, 3, 4 - and remove the locking flange and sealing ring.
- Remove the fuel line - 1 - by pressing the release button.
- Unlock the lock - 2 - and - 4 - in direction of - arrow - and remove the fuel delivery unit - 3 - upward.
CAUTION!
Danger due to escaping fuel.
• Do not tilt the fuel delivery unit because it is still filled with fuel.
Installing
• Tightening specifications, refer to => [ Fuel Delivery Unit and Suction Jet Pump Assembly Overview ] Fuel Delivery Unit and Suction Jet Pump Assembly Overview, => [ Locking Flange Cover - Tightening
Specifications ] Fuel Delivery Unit and Suction Jet Pump Assembly Overview.
Installation is in reverse order of removal, note the following:
• Replace sealing ring.
• Make sure the fuel hoses are secure.
- Install the fuel delivery unit in the fuel tank.
• The fuel delivery unit can be pushed noticeable into the baffle housing.
- Secure the fuel delivery unit - 3 - using the locks - 2 - and - 4 -.
- Install the fuel line - 1 - until it engages audibly.
- Install a new dry locking flange sealing ring.
CAUTION!
Risk of leaking.
• When inserting sealing flange, sealing ring must not be damaged or crushed.
- Bring the locking flange into the installation position.
• Tab - 2 - on right locking flange faces toward the drive direction (6 o'clock position) and must lie between tabs - 1 - and - 3 - on fuel tank.
- Tighten the locking ring.
- Check the fuel tank for leaks. Refer to => [ Fuel Tank System, Checking for Leaks ] Fuel Tank System, Checking For Leaks.
- Inspect the seal - 1 - on the locking flange covers for damage.
- If necessary, replace the seal.
- Install the connector station and the right rear relay and fuse panel.
R8 Spyder
- Install the cover module.
All Vehicles
- Connect the battery and observe safety precautions after connecting battery.
- After installing fuel delivery unit, fill vehicle with at least 5 liters of fuel.