Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

Removing

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

- Follow the guidelines for cleanliness. 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 3/4 full. Empty fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Procedures.

- Move the passenger seat all the way forward if necessary.


Risk of destroying electronic components when disconnecting the battery.

• Observe measures for disconnecting battery.

- Disconnect the battery - arrow -.






- Remove the right 1/3 rear seat.






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

- Disconnect the electrical connector - 1 - on the locking flange.






- Push the circlip - 1 - upward - arrow A - and compress the release - arrow B -.







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

• To reduce pressure in the 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.






- Press the release button and disconnect the metering pump fuel line - 1 - at the locking flange on vehicles with an auxiliary heater.


Danger due to escaping fuel.

• To prevent large quantities of fuel from leaking out of the locking flange when removing, the fuel tank may only be a maximum of 3/4 full.

- Remove locking ring using the (T10202).






- Pull the locking flange - 2 - just a little out of the fuel tank and remove the sealing ring - 1 -.






- Move the locking flange toward the right side of the vehicle, reach into the fuel tank through the gap between the locking flange and the opening and carefully guide the fuel line - 3 - out of the fuel tank.

- Remove the fuel delivery unit locking flange - 4 - from the opening in the fuel tank and lay it on the side with the lines still connected.

- Reach through the opening in the fuel tank and unlock the suction jet pump - arrows -.






- Pull suction jet pump - 2 - carefully upward with suction jet pipe - 1 - still connected.

- Disconnect suction jet pipe from suction jet pump by pressing release button.

- Remove the suction jet pump.


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

• Lay cloths below to catch the leaking fuel.

- Reach through the opening in the fuel tank and carefully remove the fuel delivery unit - 3 -.

• When removing fuel delivery unit, be sure not to bend floater arm on the fuel level sensor (G).

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, paying attention to the following:

• Replace the seal.

• When inserting fuel delivery unit, be sure not to bend floater arm on the fuel level sensor.

• Make sure the fuel hoses are secure.

- Make sure the ground wire - 1 - on the fuel pressure regulator and the locking flange is attached securely - arrows -.






- Install the fuel delivery unit - 1 - in the fuel tank with the locking flange which was moved to the side; when doing this pay attention to the installation position of the fuel level sensor.






• The fuel level sensor floater - 3 - must point toward the right side of the vehicle through the opening in the baffle.

- Insert the suction jet pump - 2 - into the fuel tank and connect the suction jet pipe.

• The suction jet pump must be guided between the 2 ridges in the baffle in the drive direction.

- Attach the suction jet pump to the fuel delivery unit. To do this, reach into the fuel tank through the opening.

• Suction jet pump must engage audibly.

- Make sure the suction jet pipe and the suction jet pump are securely locked in place.

• To improve clarity, a cross-sectional view of the fuel tank is shown.

- Move the locking flange toward the right side of the vehicle, insert the locking flange - 2 - and fuel line into the fuel tank, and carefully install the fuel line - 3 -.






- Install the new locking flange seal - 1 - over the locking flange stretched and dry.

- Make sure the fuel hoses and wires are routed correctly as illustrated:






• The fuel supply line - 1 - must be routed in front of the guide pipe - 3 -.

• The suction jet pipe - 2 - must be routed behind the guide pipe - 3 -.

• The auxiliary heater fuel supply line - 5 - must be routed behind the guide pipe - 4 -.

- Insert the guide tubes - 3 and 4 - of the locking flange into the guide holes - arrows - of the fuel delivery unit.

• The fuel delivery unit is illustrated without the fuel tank.

- Bring the locking flange into the installation position.

• The tab - 2 - on the locking flange faces toward the rear of the vehicle and must be between the tabs - 1 and 3 - on the fuel tank.






- Tighten the locking ring with (T10202).






- Connect the fuel lines - 1 and 2 -.






- Connect the connector.

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

- Install the right 1/3 rear seat.

- Connect the battery and observe safety precautions after connecting battery.

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