Fuel Delivery Unit/Fuel Level Sensor, Removing And Installing: Removing

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-- Follow all safety precautions, refer to SAFETY PRECAUTIONS .

-- Follow the rules for clean working conditions, refer to CLEAN WORKING CONDITIONS .

WARNING:

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 ¹ /₄ full.

-- If required, empty the fuel tank, refer to FUEL TANK, DRAINING .

-- Move the right front seat all the way forward.

-- Remove the rear bench seat or right rear single seat, refer to Rear Seats .

CAUTION:

Risk of damaging electronic components when disconnecting the battery.

Observe the steps for disconnecting the battery.

-- Disconnect the battery Ground (GND) cable -2-, refer to BATTERY .

Fig 1: Disconnecting Battery

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-- Cut the insulation mat near the sealing flange cover (in direction of travel on the right side under the rear seat) with scissors along the perforation and fold to the side.

Fig 2: Identifying Locking Flange Cover & Bolts -Arrows-

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

-- Disconnect the connectors -1 and 2- on the sealing flange by releasing the connector safety catch.

Fig 3: Identifying Connectors

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WARNING:

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

To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

-- Press the release button and disconnect the fuel line -2- from the sealing flange.

-- For vehicles with a parking heater: Press the release button and disconnect the fuel line -1- to the parking heater metering pump at the sealing flange.

WARNING:

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 ¹ /₄ full.

Fig 4: Identifying Fuel Lines

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-- Remove the locking ring using the Wrench - Fuel Sending Unit T10202.

Fig 5: Identifying Fuel Sending Unit Wrench

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-- Remove the sealing flange -1- through the opening in the fuel tank.

-- Remove the seal -4- through the opening in the fuel tank.

-- Press the release button and disconnect the fuel line -2- from the sealing flange.

-- Release the connector safety catch and disconnect the connectors -3 and 5-.

Fig 6: Identifying Sealing Flange, Fuel Lines, Connectors And Seals

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-- Reach in the fuel tank and release the cover -1- on the retainers -2 and 3-.

-- Tilt the cover upward -arrow A-, unclip from the baffle housing -arrow B- and remove from the fuel tank.

Fig 7: Identifying Cover And Retainers

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-- Reach in the fuel tank and pull the cover -1- >>open<< in direction of -arrow- off the retainers on the baffle housing.

Fig 8: Removing Cover

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-- Remove the cover from the fuel tank.

-- Reach in the fuel tank and disconnect the connector -1- by releasing the connector safety catch.

-- Reach in the fuel tank and pull the fuel delivery unit by the tab -3- in direction of -arrow A- out of the retainers on the baffle housing.

-- Pull the fuel delivery unit fuel screen -4- upward in direction of -arrow B- toward the opening in the fuel tank.

-- Press the release, pull the fuel delivery unit toward the opening in the fuel tank and remove the fuel line -2-.

Fig 9: Identifying Connector, Fuel Line, Tab And Screen

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-- Remove the fuel delivery unit fuel screen -2- from the opening in the fuel tank.

Fig 10: Removing Fuel Delivery Unit Screen

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-- Reach in the fuel tank, carefully turn the fuel delivery unit -1- -arrow- and guide it out of the fuel tank.

Fig 11: Removing Fuel Delivery Unit

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WARNING:

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

Lay cloths below to catch the leaking fuel.

-- Carefully remove the entire fuel delivery unit -1- with screen and wires from the fuel tank -arrow-.

-- Disconnect the fuel line -2-.