Fuel Lines, Removing And Installing: Notes

Special tools and workshop equipment required 

• Engine Bung Set:VAS 6122 
  Fig 1: Engine Bung Set

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Removing

-- Seal all the open lines and connections with clean plugs from the Engine Bung Set:VAS 6122  .

-- Remove the underbody trim panel in front of the right rear axle. Refer to Underbody Trim Panel .

-- Loosen the underbody trim panel on the right side and lower it. Refer to Underbody Trim Panel .

-- Disconnect the fuel lines on the underbody. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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-- Unclip the bracket -1- from the underbody -arrows-.

-- Unclip the bracket -1- from the fuel lines.

-- Secure using a pulling aid (for example a cable or string) on the fuel lines.

-- This pulling aid makes the reinstallation easier, to do so select enough length.

-- Use adhesive tape to secure the pulling aid.

-- Lower the vehicle with the hoist.

-- Remove the fuel supply line -1- and -2-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Unclip the fuel lines -1- and -2- from the bracket -arrow- on the coolant expansion tank -3-.

-- Disconnect the connector -1-.

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-- Open the bracket and remove the coolant hoses from the engine.

-- Release the retainers with a screwdriver -arrow- and move the coolant expansion tank to the side.

-- Open the bracket for the refrigerant lines on the right wheel housing.

-- Unclip the refrigerant lines. Refer to REFRIGERANT LINES WITH INNER HEAT EXCHANGER, REMOVING AND INSTALLING .

LHD vehicles:

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-- If equipped remove the heat shield -1- from the ABS Hydraulic Unit -N55-.

-- To do so, unclip the heat shield -1- from the bracket -2- -arrow-.

Vehicles with Parking Heater:

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-- Remove the front section of the wheel housing liner or right front wheel housing liner. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Unlock and remove the fuel line -7-.

-- Unclip the fuel line from the bracket and guide out.

-- Unclip the bracket for the refrigerant lines on the body. Refer to REFRIGERANT LINES WITH INNER HEAT EXCHANGER, REMOVING AND INSTALLING .

-- Guide the fuel line under the refrigerant lines and the engine mount.

Continuation for All Vehicles:

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-- Unclip the shield -1- from the stud bolt on the body -arrows-.

-- Unclip the shield -1- from the longitudinal member -2-.

-- If equipped, loosen the clip -4- for the parking/auxiliary heater fuel line -3- from the body.

-- Unclip the bracket -2- for the shield from the longitudinal member.

-- Remove the lines upward.

-- At the same time turn the lines, but do not tear!

-- Unclip the lines and remove the shield upward.

Installing:

-- Remove the pulling aid from the old lines.

-- Pay attention that the plug is seated correctly on the new lines.

-- Seal the lines with suitable plugs from the Engine Bung Set:VAS 6122  .

-- Insert the lines as shown in the shield guide and clip in. Refer to Line Installation Positions on the Shield: .

-- The fuel lines are clipped in at the top of the shield only after guiding them in. Refer to Line Installation Positions on the Shield: .

-- Secure the pulling aid on the fuel lines.

-- Use adhesive tape to secure the pulling aid.

-- Pay attention that the pulling aid is only secured in the front area of the lines.

-- Seal the shield at the bottom from the slotted guide with adhesive tape so that the lines do not slide out.

-- Place the fuel lines together with the shield on the opening in the longitudinal member.