Fuel Filter: Service and Repair

Fuel Tank With Attachments And Fuel Filter, Removing And Installing (Vehicles With Engine Code BDC)







1 Cap
2 Seal
- Replace if damaged
3 Mounting screw
4 Tank lid unit
- with rubber cap
5 Vent line
- Black
- Check for secure fitting
6 Ground (GND) connection
- Check for secure fitting
7 Vent line
- white
- Check for secure fitting
- to disengage, squeeze together at front
- to EVAP canister, item no. 5
8 Gravity valve
- To remove, unclip valve upward from connection
- Checking valve for throughput: Valve vertical: open, Valve tilted 45 degree: closed
9 Seal
- Replace if damaged
10 Change-over valve
- to remove, unclip valve sideways from connection
- before installing, unscrew cap, item 1
11 Vent line
- Black
- Check for secure fitting
- to EVAP canister, item no. 4
12 Pressure retention valve
13 Vent line
- Black
- Check for secure fitting
- clipped in at top of fuel tank
14 Fuel tank
15 Clamping washer
16 Heat shield
- for fuel tank
17 25 Nm
18 Tightening nut, 2 Nm
19 Cover for fuel tank
20 Tension strap
- Note varying lengths
- Installation position: Locating point (hole) faces direction of travel
21 Supply line
- Black
- Check for secure fitting
- to remove from fuel filter, press release buttons on connecting piece
- to fuel supply line at fuel distributor, Item 3
22 Fuel filter
- Installation position: Arrow points in direction of flow
23 Screw clamp
- Note installed position, see Fig. 4
24 Vent line
- white
- Check for secure fitting
- Clipped in sideways at fuel tank
- to Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- , item 10
25 Seal
- Replace if damaged
- to install, place into opening of fuel tank when dry
- only coat with fuel when installing Fuel Pump (FP) flange
26 Fuel pump
- Note installation position of flange at fuel tank, see Fig. 1
- Checking Fuel Pump (FP)
- Clean strainer if dirty
27 Union nut, 75 Nm
28 Supply line
- Black
- Check for secure fitting
- Clipped in sideways at fuel tank
- to remove from flange and fuel filter, press release buttons on connecting piece
29 Return line
- blue or with blue marking
- Clipped in sideways at fuel tank
- Check for secure fitting
- to remove from flange, press release buttons on connecting piece
- from fuel return line at fuel distributor, Item 2
30 Connector
- Black, 4-pin
- for sender for fuel gauge -G- and Fuel Pump (FP) -G6-
31 10 Nm


Fig. 1 Installation position of Fuel Pump (FP) flange







Marking on sensor must align with marking on fuel tank (arrows).
Blue or blue marked return line -1- at connection marked -R-.
Black supply line -2- at connection marked -V-.


NOTE: After installing Fuel Pump (FP) flange, check whether supply, return and vent lines are still clipped in at fuel tank.


Fig. 2 Checking change-over valve







Lever in rest position: closed
Lever pressed in direction of arrow: open


NOTE: Before installing bleeder valve, unscrew cap from fuel tank.


Fig. 3 Checking pressure retaining valve







- Check direction of flow of valve:

A) Connections 1 - 1:
- Flow in both directions
- Connection -2- is closed

B) Connections 1 - 2:
- Flow in both directions
- Connection -3- is closed

C) Connections 1 - 2:
- Flow in one direction
- Connection -3- is closed
- in case of vacuum at connection -1-, valve must close

Fig. 4 Installation position of fuel filter screw-type clamps







NOTE: Fuel filter is shown in illustration from the front.


- Install screw-type clamps (arrow) as shown in illustration.
Make sure there is enough distance between clamp lock and fuel tank. Dimension "a" must be at least 5 mm.