Fuel Delivery
Fuel Delivery
Special tools, testers and auxiliary items required
• Fuel Tank Sender Unit Tool (T40068 A)
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 passenger seat all the way forward if necessary.
Danger of causing damage to other electronic components when disconnecting the battery.
• Complete the steps for disconnecting the battery.
- Disconnect the battery.
- Remove the rear bench seat.
- Remove the locking flange cover - arrows -.
- Disconnect the connectors - 1 and 2 - on the locking flange.
- If necessary, disengage the electrical connector - 3 - to the auxiliary heater metering pump at the locking flange and lay it aside.
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.
- If necessary, disconnect the fuel line - 1 - to the auxiliary heater metering pump at the locking flange by pressing the release button.
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.
- Use a (T40068 A) to remove the union nut - arrow -.
• When union nut is loosened, plastic catch on threaded ring breaks off - ignore.
- Remove the locking flange - 2 - with fuel filter from the fuel tank and tip it slightly to the left side of the vehicle.
- Remove the seal - 1 -.
- Pull the locking flange with fuel filter away from the fuel delivery unit slightly - arrow A -.
- At the same time, tilt the locking flange with fuel filter out of the fuel tank - B arrows -, being especially careful of the retaining plate with the ground connection - 3 - and the fuel line - 4 -.
There is a risk of fuel leaking out from the filled fuel delivery unit.
• Lay cloths below to catch the leaking fuel.
- Pull the locking flange - 2 - with fuel filter away from the fuel delivery unit - 1 - slightly again - arrow A -.
- Tilt the fuel delivery unit to the left side of the vehicle - arrow B - and pull it out of the fuel tank slightly.
• When removing fuel delivery unit, be sure not to bend floater arm on the fuel level sensor.
- Remove the fuel level sensor - 3 - from the fuel tank opening.
- Remove the suction line - 3 - by pressing the release - 1 -.
- Disconnect the connector - 2 - for the fuel level sensor 2 (G169) by pressing the release - arrow -.
• The illustration shows the fuel delivery unit with the fuel tank.
Installing
• Tightening specification, refer to => [ Fuel Delivery Unit and Fuel Level Sensor Overview ] Fuel Delivery Unit and Fuel Level Sensor Overview.
Install in reverse order of removal. Note the following:
• Replace the sealing ring and the union nut.
• When inserting the fuel delivery unit, do not bend the floater arm on the fuel level sensor.
• Make sure the fuel hoses are secure.
- Guide the suction line - 3 - out of the fuel tank and connect it until it engages audibly.
- Connect the electrical connector - 2 - for the fuel level sensor 2.
- Make sure the Ground (GND) wire - arrow - is connected securely to the fuel pressure regulator retaining plate.
- Insert the fuel level sensor - 3 - in the fuel tank.
- Pull the locking flange - 2 - with fuel filter away from the fuel delivery unit - 1 - slightly again - arrow A -.
- Bend the fuel delivery unit to the left side of the vehicle and tilt it into the fuel tank - arrow B - while being careful of the fuel level sensor - 3 -.
- Pull the locking flange - 2 - with the fuel filter away from the fuel delivery unit slightly - arrow A -.
- At the same time, tilt the locking flange with fuel filter into the fuel tank - B arrows -, being especially careful of the retaining plate with the ground connection - 3 - and the fuel line - 4 -.
- Stretch the new sealing ring - 1 - over the locking flange and insert it in the groove on the fuel tank.
- Place the union nut - 1 - on your left arm and push the locking flange - 2 - forcefully into installation position with your left hand - arrow -.
• The tab - 4 - on locking flange must lie between tabs - 3 and 5 - on threaded ring.
- Slide the union nut - 1 - off your left arm using your right hand while your left hand keeps holding the locking flange - 2 - down firmly - arrow -.
- Position the union nut - 1 - with your right hand so the double ridge - 5 - on the ribs is over the lug - 3 - on the locking flange (approximately "10 o'clock" position). This makes sure the union nut engages at the beginning of the threads immediately when tightening it - 4 -.
- Press the locking flange down firmly with a screwdriver - arrow -.
- Turn the union nut approximately 480° with your right hand until the double ridge - 1 - is in approximately "2 o'clock position" while keeping the locking flange pressed down firmly with your left hand.
There is a risk of the locking flange threaded connection leaking.
• Press the locking flange down firmly when tightening the union nut so it does not rotate too.
- Tighten the union nut using (T40068 A).
• Verification: The double ridge - 1 - must now be between "7 and 8 o'clock".
- Connect fuel lines - 1 and 2 -.
- Connect the connectors.
- Install the right locking flange cover => [ Locking Flange Cover - Tightening Specifications ] Fuel Tank With Attachments Overview.
- Install the rear bench seat.
- 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 (5.28 quarts) of fuel.
- Vehicles with auxiliary heater: To vent the fuel line to the auxiliary heater metering pump, run for 10 minutes at wide open throttle.