Fuel Delivery Unit, Removing and Installing

Fuel Delivery Unit, Removing And Installing

Special tools, testers and auxiliary items required







- Wrench T10202

Removing
Observe safety precautions.
Observe rules for cleanliness.

CAUTION:
- To remove the fuel delivery unit, the fuel tank may only be filled to a maximum of 3/4. Drain fuel tank if necessary.
- Observe procedures for disconnecting battery.







- Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 - .







- With ignition switched off, disconnect Battery Ground (GND) strap - arrow - .

Sedan:
- Remove carpeting in luggage compartment.
- Fold forward right rear seat backrest, if necessary.

Wagon:
- Remove left 1/3 backrest.
- Remove left side luggage compartment trim and dirt tray.

All models:







- Unbolt cover for locking flange in luggage compartment - arrows - .







- Disconnect electrical harness connector - arrow - at locking flange.







- Mark fuel supply line - 1 - and fuel return line - 2 - .

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

- Pull both lines from locking flange, by pressing release buttons.

CAUTION: The fuel delivery unit may only be removed when fuel tank is maximum 3 / 4 filled. Otherwise, a large amount of fuel will spill out.







- Remove locking ring with wrench T10202 .
- Lift fuel delivery unit slightly out of fuel tank opening and remove seal.







- If fuel delivery unit is still inserted in fuel tank, slide locking flange slightly to side.
- Reach through the gap between locking flange and installation opening in fuel tank and pull off suction jet line - 1 - from suction jet pump, by pressing release button.
- Release suction jet pump - arrows - and remove it.
- Remove fuel delivery unit.

NOTE:
- When removing fuel delivery unit, be sure not to bend floater arm of fuel level sensor G .
- Be aware that fuel is still in the fuel delivery unit.

Installing
Installation is in reverse order of removal. Note the following:

NOTE:
- Replace seal.
- When installing fuel delivery unit, be sure not to bend floater arm of fuel level sensor G .
- Make sure fuel hoses are seated securely.







- Insert fuel delivery unit into fuel tank.
- Clip in suction jet pump on fuel delivery unit. To do so, insert hand into gap between locking flange and installation opening of fuel tank.
- Suction jet pump must engage audibly.
- Verify that the suction jet pump is securely engaged.
- Push suction jet pipe - 1 - onto connection of suction jet pump until it engages audibly.
- Install new locking flange seal dry.
- Press locking flange down against spring pressure and bring it into installation position.







- Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

NOTE: - Arrow - points in direction of travel.







- Tighten locking ring.







- Install fuel supply line - 1 - and fuel return line - 2 - according to marking.
- Connect electrical harness connector.
- Connect battery. Observe safety precautions after connecting battery.

Torque specifications
Locking ring for fuel delivery unit 145 Nm