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

Condition

The fuel tank may be a maximum of ³ /₄ full

-- Refer to Fuel Tank, Draining .

-- Remove the installation opening cover. Refer to Installation Opening Cover, Removing and Installing .

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Disconnect the connectors -1- and -2-.

Fig 1: Connector on the Fuel Delivery Unit

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Vehicles with Parking Heater:

-- Disengage the connector -2- for the parking heater Metering Pump -V54- at the sealing flange and lay it aside.

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Continuation for all vehicles

Vehicles with fuel pump control module:

-- Remove the Fuel Pump Control Module -J538-. Refer to Fuel Pump Control Module J538, Removing and Installing .

Continuation for all vehicles

CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place a clean cleaning cloth around the connection point and slowly open the connection point.

-- Disconnect the fuel supply line -1-. Refer to Connector Couplings, Disconnecting .

Fig 2: Fuel Lines to the Fuel Delivery Unit

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Vehicles with Parking Heater:

-- Remove the parking/auxiliary heater fuel line -2-. Refer to Parking/Auxiliary Heater Fuel Line, Removing and Installing .

Vehicles with Diesel Engine:

CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place a clean cleaning cloth around the connection point and slowly open the connection point.

-- Disconnect the fuel return line -2-. Refer to the appropriate service information .

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Continuation for all vehicles

-- Turn the locking ring -2- counter-clockwise, using a Wrench - Fuel Sending Unit :T10202 -A-.

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-- Remove the locking ring -2- from the flange -1-.

-- Place a cleaning cloth underneath to catch any escaping fuel.

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-- Lift the flange -1-, until the seal -2- is accessible.

-- Loosen the seal -2- and remove the flange -1-.

-- Make sure that the sensor is not damaged.

Vehicles with a gasoline engine:

-- Carefully remove the fuel lines from the fuel tank opening.

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-- Disconnect the suction jet line -1- and delivery line -2-.

Continuation for all vehicles

AWD vehicles and line connections at the bottom of the fuel delivery unit:

-- Place a cleaning cloth underneath to catch any escaping fuel.

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-- Press the release at the connecting piece and remove the suction jet line -3-. Refer to Connector Couplings, Disconnecting .

-- Pull the clamp -2- in the -direction of the arrow B-.

-- Remove the suction jet pump delivery line -1- in the -direction of the arrow A-.

Continuation for all vehicles

Vehicles with Diesel Engine:

-- Place a cleaning cloth underneath to catch any escaping fuel.

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-- Press the release at the connecting piece and remove the suction jet line -1-. Refer to the appropriate service information .

-- Press the retainers -2- and -3- and remove the suction jet pump delivery line.

Continuation for all vehicles

Vehicles with diesel engine and parking heater:

-- Press the release at the connecting piece and remove the suction jet line -1-. Refer to the appropriate service information .

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-- Press the retainers -2- and -3- and remove the suction jet pump delivery line.

Continuation for all vehicles

-- Remove the fuel delivery unit -1- with the sensor -2-. At the same time turn and tip the fuel delivery unit.

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-- Make sure that the sensor floater arm is not damaged.