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

Special tools and workshop equipment required

NOTE:

After removing the fuel delivery unit, check the fuel tank for visible contamination and clean if necessary.

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions. Refer to FUEL SYSTEM GUIDELINES FOR CLEAN WORKING CONDITIONS .

Removing

-- The fuel tank may be a maximum of ³ /₄ full. This ensures the fuel level is below the fuel delivery unit flange.

-- Drain the fuel tank. Refer to FUEL TANK .

-- Switch off the ignition and all electrical equipment.

-- Unclip the cover -1- at the tabs in direction of -arrows- using the : 3409 .

Fig 1: Identifying Right Cover

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-- Make sure the connector -1- is secure. If the connector was not connected correctly, it could cause a malfunction.

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

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-- Release and disconnect the connector -1-.

-- Check the contacts on the connector and on the fuel delivery unit for damage.

CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Remove the fuel line -2- from the fuel delivery unit flange -3-.

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

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-- Collect escaping fuel with a cleaning cloth.

-- Open the locking ring using the : T10202 and lift the flange slightly.

Fig 4: Identifying Removal Of Locking Ring Using Wrench T10202

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

-- Remove the fuel delivery unit flange from the opening in the fuel tank as far as possible.

Fig 5: Identifying Installation Of Flange On To Delivery Unit

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-- Remove the seal -A- from the fuel tank and pull it above the flange.

Fig 6: Identifying Sealing Ring Pulled Over Flange

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-- Disconnect and remove the connector coupling -2-.

Fig 7: Identifying Coupling

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-- Release the evacuation line -1- -arrows- and remove it.

-- Remove the delivery unit through the fuel tank opening.

NOTE:

If the delivery unit is being replaced, the old delivery unit must be emptied before disposing of it.

Follow all disposal regulations.