Procedure 1
Suction Jet 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.
• To remove suction jet pump, fuel tank should be completely empty. 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 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.
- Remove the left single seat and the left 2/3 seat bench seat cushion in the second row of seats.
Risk of injury.
• Wear protective gloves.
- Cut the floor covering along the perforation - arrows - on the left side with a carpet knife - 1 -.
- Fold carpet cut-out to side - arrow -.
- Remove the nuts - 1 to 4 - and remove left locking flange cover.
- Disconnect the electrical connector - arrow - on the left locking flange.
- Remove locking ring with (T10202).
- Pull the left locking flange - 3 - slightly out of the fuel tank.
- Disconnect the connector - 2 - underneath the left locking flange.
- Remove the sealing ring - 1 - from the fuel tank.
- Reach into the fuel tank opening and remove fuel level sensor 2 (G169) out of the guide - 4 - - arrow 2 -. - 3 - by pressing the release tab - arrow 1 -.
- Remove suction jet pump from guide - 3 - - arrow 2 - by pressing locking tabs at the same time - arrow 1 -.
• The suction jet pump is illustrated without the fuel tank.
- Carefully remove suction jet pump - 4 - through the fuel tank opening.
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.
• Verify that the suction jet pump is securely engaged.
- Push the suction jet pump fuel lines through the left opening on the fuel tank into the right fuel tank chamber.
- Insert the suction jet pump into guide and press it down until it audibly engages.
- Insert fuel level sensor 2 in guide until it engages audibly.
- Connect electrical connector - 2 - underneath the left locking flange - 3 -.
- Install the new sealing ring - 1 - for the left locking flange 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 fuel tank.
- 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 right locking flange dry.
- Connect electrical connectors - 1 and 2 - on 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 locking flange covers. 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 single seat cushion or the 2/3 seat bench in the 2nd 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.