Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Scissors

Removing

- Follow all safety precautions. Refer to => [ Safety Precautions ] Safety Precautions.

- Follow the guidelines for clean working conditions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

Danger due to escaping fuel.

• To prevent large quantities of fuel from leaking from the fuel delivery unit when removing, the fuel tank may only be a maximum of 1/4 full.

- Empty the fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Procedures.

- Move the right front seat all the way forward.

- Remove the rear bench seat or the lower seat frame/rear seat backrest.






Danger of causing damage to the other electronic components when disconnecting the battery.

• Complete the steps for disconnecting the battery.

- Disconnect the Ground (GND) cable - 2 - from the battery.

- Cut the insulation mat near the locking flange cover along the perforation with scissors and fold it to the side.






- Remove the bolts - arrows - and remove the locking flange cover - 1 -.

- Disconnect the connectors - 1 and 2 - on the locking flange.













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

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

- Disconnect the fuel line - 2 - at the locking flange by pressing the release button.

• Disregard - 1 -








Danger due to escaping fuel.

• To prevent large quantities of fuel from leaking from the fuel delivery unit when removing, the fuel tank may only be a maximum of 1/4 full.

- Remove the locking ring using the (T10202).

- Remove the locking flange - 1 - through the opening in the fuel tank.






- Remove the seal - 4 - through the opening in the fuel tank.

- Disconnect the fuel line - 2 - from the locking flange.

- Disconnect the connectors - 3 and 5 -.

- Reach into the fuel tank and unlock the cover - 1 - at the catches - 2 and 3 -.






- Swivel the cover upward - arrow A -, unclip it from the baffle housing - arrow B - and remove it from the fuel tank.

- Reach into the fuel tank and pull the cover - 1 - in direction of - arrow - open the catches on the baffle housing.






- Remove the cover from the fuel tank.

- Reach into the fuel tank and disconnect the connector - 1 -.






- Reach into the fuel tank and pull the fuel delivery unit - 3 - in direction of - arrow A - off the catches on the baffle housing.

- Pull the fuel delivery unit fuel screen - 4 - upward in direction of - arrow B - toward the opening in the fuel tank.

- Pull the fuel delivery unit toward the opening in the fuel tank and disconnect the full line - 2 -.

- Remove the fuel delivery unit fuel screen - 2 - through the opening in the fuel tank.






- Reach into the fuel tank and carefully turn the fuel delivery unit - 1 - - arrow - and guide it out of the fuel tank.








There is a risk of fuel leaking out from the filled fuel delivery unit.

• Lay cloths below to catch the leaking fuel.

- Remove the fuel delivery unit - 1 - with the screen and the electric wire carefully from the fuel tank - arrow -.

- Disconnect the fuel line - 2 -.

Installing

- Guide the fuel line - 2 - out of the fuel tank and attach it to the fuel delivery unit so that it audibly latches.

- Guide the fuel delivery unit - 1 -, the screen and the electric wires into the fuel tank.

- Reach into the fuel tank and carefully turn the fuel delivery unit - 1 - and screen into its installed position - arrows -.






- Reach into the fuel tank and connect the fuel line - 2 - to the fuel delivery unit. The fuel line must audibly latch.






- Push the fuel delivery unit - 3 - into the catches on the baffle housing in direction of - arrow -.

- Connect the electrical connector - 1 - and make sure it engages.

Install in reverse order of removal. Note the following:

• Tightening specification, refer to => [ Fuel Delivery Unit Overview ] Fuel Delivery Unit Overview.

• Replace seal.

• Make sure the fuel hoses are secure.

- Connect the connectors - 3 and 5 - and make sure they engage.






- Install the fuel line - 2 - until it audibly latches on the locking flange.

- Install the new locking flange seal - 4 -. The seal must dry.

- Insert the locking flange - 1 - into the fuel tank.








Risk of leaking.

• When inserting sealing flange, sealing ring must not be damaged or crushed.

- Bring the locking flange into the installation position.

• The tab - 2 - on the right locking flange must be located between tabs - 1 and 3 - on the fuel tank.

• The arrow on the locking flange must point in direction of travel.

- Attach the fuel lines so that they audibly latch.

- Connect the connectors and make sure they are secure.

- Install the right locking flange cover. Refer to => [ Locking Flange Cover - Tightening Specifications ] Fuel Delivery Unit Overview.

- Install the rear bench seat or the lower seat frame/rear seat backrest.

- Connect the battery. Be sure to read the procedures after connecting the battery.

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