Fuel Delivery Unit/Fuel Level Sensor: Installing

Install in the reverse order of removal. Note the following when doing this:

NOTE:

Pay attention to the installed position of all the components.

The coupling must audibly engage when locking.

Note the color coding when installing the coupling, refer to Coupling Allocation !

Pull on the coupling to make sure it is secure.

Disconnecting the coupling, refer to COUPLING, DISCONNECTING .

-- Install the fuel delivery unit without the flange. Be careful not to bend the fuel level sensor.

FWD

Fig 1: Identifying Fuel Delivery Unit Without Flange

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-- Attach the suction jet pump intake line -arrows- and lock it into place.

-- Connect the coupling -2-.

Vehicles with AWD:

Fig 2: Disconnecting/Connecting Fuel Lines

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-- Connect the suction jet pump -B- and the wire -A-.

Continuation for All Vehicles

Fig 3: Placing Flange On Delivery Unit

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-- Place the flange -1- on the delivery unit -2-. While doing so pay attention to the installed position of the guide pins -arrows-.

-- Connect the flange to the delivery unit.

NOTE:

Make sure that the hoses are seated in the correct positions.

The connector coupling must >>audibly<< engage when locking.

Note the color coding when installing the coupling, refer to Coupling Allocation !

Pull on the connector coupling to make sure it is secure.

Disconnect the connector couplings, refer to COUPLING, DISCONNECTING .

-- Pull the seal -A- over the flange and insert it into the fuel tank opening.

Fig 4: Identifying Sealing Ring Pulled Over Flange

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-- Install the dry fuel delivery unit seal into the opening in the fuel tank.

-- Coat the inner side of the sealing ring with fuel.

-- Bring the locking flange into the installed position and press down against the spring force.

Fig 5: Fuel Delivery Unit Flange Installed Position

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The latch -2- from the locking flange must lie between tabs -1- and -3-.
-Arrow- indicates direction of travel.

-- Insert the locking ring and fasten using the Wrench - Fuel Sending Unit T10202. Tightening specification, refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR OVERVIEW .

Fig 6: Identifying Removal Of Locking Ring Using Wrench T10202

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CAUTION:

Do not bend the Wrench - Fuel Sending Unit T10202 and push hard on the locking ring. If the wrench slides down, the fuel delivery unit can be damaged.

-- Connect the connector -1-.

Fig 7: Identifying Connector -1-, Fuel Line -2- And Fuel Delivery Unit -3-

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-- Connect the fuel line -2-.

-- Pull on the coupling and connectors to make sure they are fastened securely.

The -arrow- on the cover points in the direction of travel.

Fig 8: Identifying Direction Of Arrow On Cover
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Tightening Specification

Component	Nm
Lock ring	110