Procedure 1

Fuel Delivery Unit and Transfer Fuel Pump

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Carpet knife, commercially available

Removing

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

Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.

• The fuel tank must be completely empty to remove the fuel delivery unit. Refer to => [ Fuel Tank with Reducing Agent Metering System, Draining ] Procedures.

- Remove the right single seat in the second row of seats.

Risk of injury.

• Wear protective gloves.

- Cut the floor covering along the perforation - arrows - on the right side with a carpet knife - 1 -.






- Fold carpet cut-out to side - arrow -.






- Remove nuts - 1 to 4 - and remove right locking flange cover.

• Place a clean cloth under the separating location to catch any fuel that may leak out.

Very hot fuel can burn skin.

• In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.

• Wear protective gloves.

• Wear safety glasses.

There is a risk of injury because the fuel is under pressure.

• To reduce pressure in the fuel system, lay a clean cloth around the connector and carefully loosen the connector.

Vehicles with Vertical Fuel Filter

- Disconnect the fuel return line - 1 - and the fuel supply line - 2 - from the right locking flange by pressing the release buttons.






- Disconnect the connector - 3 - on the right locking flange.

Vehicles with Horizontal Fuel Filter

- Disconnect the fuel return line - 1 - and the fuel supply line - 2 - from the right locking flange by pressing the release buttons.






- Disconnect the connectors - 3 - and - 4 - on the right locking flange.

All Vehicles

- Vehicles with auxiliary heater: Also separate the fuel supply line to the auxiliary heater at the metering pump, by pressing the release buttons.

- Remove locking ring with (T10202).






- Pull the right locking flange off the fuel tank slightly.






- Disconnect the connectors - 1 and 2 - underneath the right locking flange.

- Disconnect the fuel lines - 1 and 3 - underneath right locking flange by pressing the release button.






- Reach into the opening in the fuel tank and disconnect the auxiliary heater supply line - 5 - from the fuel delivery unit by pressing the releases.

- Remove the right locking flange - 2 - and sealing ring - 4 -.

- Reach into the opening in the fuel tank and disconnect the delivery line - 7 - by pressing the releases.

- Disconnect the suction jet pipe - 6 - to suction jet pump by pressing release button.

- Reach into the opening in the fuel tank and turn the fuel delivery unit - 1 - counterclockwise 15° - arrow - to release (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 line out of the opening in the fuel tank and remove the fuel delivery unit upward.

• Be sure there is still some fuel inside the fuel delivery unit.

Installing

Install in reverse order, paying attention to the following:

• For the correct tightening specifications, refer to => [ Fuel Delivery Unit, Suction Jet Pump and Fuel Level Sensor Overview ] Fuel Delivery Unit, Suction Jet Pump and Fuel Level Sensor Overview.

• 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.

- Turn the fuel delivery unit - 1 - clockwise 15° to secure (bayonet connection).

- Push the suction jet pipe - 6 - onto the suction jet pump until it engages audibly.






- Attach the supply line - 7 - until it audibly latches to the fuel delivery unit.

- Attach the supply line - 5 - to the auxiliary heater until it audibly latches to the fuel delivery unit.

- Attach the fuel lines - 1 and 3 - to the right locking flange - 2 - until they audibly engage.

- Install the new sealing ring - 4 - for the locking flange dry.

- Connect electrical connectors - 1 and 2 - on the underside of right locking flange.






- Bring the right locking flange into the installation position:

• Tab - 2 - on right locking flange faces toward arrow marking and must lie between tabs - 1 and 3 - on fuel tank.






- Install the right locking flange cover. Refer to => [ Locking Flange Cover - Tightening Specifications ] Fuel Delivery Unit, Suction Jet Pump and Fuel Level Sensor Overview.

- Install the frame into the floor covering. and to the Parts Catalog.

- Install the right single seat in the second row of seats.

- Vehicles with auxiliary heater: Bleed the fuel supply line to the metering pump. Refer to => [ Fuel Supply Line to Metering Pump, Vehicles with Auxiliary Heater, Bleeding ] Fuel Supply Line to Metering Pump, Vehicles With Auxiliary Heater, Bleeding.

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