All Wheel Drive (AWD) Vehicles

All Wheel Drive (AWD) Vehicles

Observe safety precautions. Safety Precautions When Working on Fuel Supply System
Observe rules for cleanliness. Vehicle Damage Warnings

Special Tools and Equipment







- 3087 wrench for tank sensor







- Fuel Pump Wrench 3307

Removing
- Note and if necessary obtain radio code (for vehicles equipped with coded anti-theft radio).







- Remove cover above the battery (arrows).

NOTE: For vehicles without separate battery cover: Remove plenum chamber cover.







- Disconnect battery Ground (GND) strap (arrow) with the ignition switched off.
- Open fuel tank cap briefly and then close again.
- To remove the Fuel Pump (FP), the fuel tank may only be filled to a maximum of 1/4. Empty fuel tank if necessary.
- Remove rear seat bench.
- Unscrew cover for connector flange at left beneath rear seat bench







- Carefully disengage and disconnect electrical 4-pin harness connector (arrow).

CAUTION: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.







- Mark fuel supply line -1- and fuel return line -2- and disconnect from connector flange (right side of vehicle).

CAUTION: Connector flange may only be opened when fuel tank is maximum 1/4 full. Otherwise, a large amount of fuel will spill out.







- Use 3087 wrench to remove locking ring.
- Pull connector flange and sealing ring from opening of fuel tank.







- Disconnect both harness connectors -1- and -2- to fuel gauge on inside of connector flange.







- Unclip union piece -1- at lower part of baffle housing, to do so, carefully press union piece toward left side of vehicle and lift upward (arrow).
- Disconnect fuel return line -2- from union piece, release hose coupling for return line to do this.

NOTE: Baffle housing is shown without fuel tank for the sake of illustration.







- Insert fuel pump wrench 3307 through fuel tank opening and position on inner part of baffle housing.
- Rotate inner part of baffle housing with pump toward left approx. 15 degree to stop.







^ Notch -1- aligns with marking -2- (bayonet connection)
- Remove Fuel Pump (FP) with inner part of baffle housing.

NOTE: When replacing Fuel Pump (FP) unit, empty old Fuel Pump (FP) unit before disposing.

Installing
Installation is the reverse of removal, noting the following:

NOTE: Secure all hose connections using hose clamps appropriate for the model type.







- Insert inner part of baffle housing into outer part of baffle housing in fuel tank so the notch -1- on inner part of baffle housing aligns with marking -2- on outer part of baffle housing.
- Inner part of baffle housing can be pressed downward significantly and noticeably.







- Insert fuel pump wrench 3307 through fuel tank opening and position on inner part of baffle housing.
- Rotate inner part of baffle housing with pump toward right approx. 15 degree to stop.







^ Notch -1- aligns with marking -3- (bayonet connection)







- Insert rigid line -3- and hose line -5- into the corresponding holes of baffle housing -6-.
- Press on return line -1- on union piece -4- until hose coupling engages.

NOTE:
- Always use new O-rings -7- for the fuel return line.
- Coat O-rings for fuel return line with fuel or with lubricant.

- Clip in rigid line -3- on union piece -4-, while doing this the union piece engages itself into baffle housing -6-.







- Connect harness connectors -1- and -2- for fuel gauge on inside of connector flange.
- Insert new, dry seal for connector flange into opening of fuel tank.







- When connecting the connector flange, ensure clearance of electrical wires -2- to Fuel Pump (FP) and of return hose -1-.







- When installing, turn connector flange in direction of arrow as shown in illustration.







- Insert connector flange in fuel tank, note installation position:
- Marking on connector flange -1- must align with marking on fuel tank -2-.

NOTE: Arrow points in direction of travel.







- Tighten locking ring (120 Nm).
- Install supply and return hose according to marking.
- Install cover for connector flange so that the protrusion lies over the harness connector.
- After connecting battery, enter anti-theft code for radio.
- Fully close power windows to stop.
- Then activate all power window switches ("up") for at least one secondto activate automatic window raising/lowering.
- Set clock to correct time.
- Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data.
- Generate readiness code.


Tightening torques
Component Nm
Locking ring for Fuel Pump (FP) 120
Battery terminal to battery post 5