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

Install in reverse order of removal. Note the following:

NOTE:

Replace the seal.

Make sure the fuel hoses are secure.

When inserting fuel delivery unit, be sure not to bend floater arm on the Fuel Level Sensor -G-.

-- Route the Ground (GND) cable as illustrated.

Fig 1: Routing Ground (GND) Cable

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GND Cable to Locking Flange
Locking Flange
Fuel Pressure Regulator
GND Cable to Fuel Pressure Regulator

Make sure the fuel hoses are routed correctly:

Fig 2: Routing Fuel Hoses Correctly

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-- Connect the fuel supply hose -1- to the fuel delivery unit -7-.

-- Insert the fuel return hose -4- into the guide on the fuel delivery unit -7-.

-- Insert the guide tubes -2 and 6- with the locking flange pressure spring -3- into the guides on the fuel delivery unit.

-- If the vehicle has a parking heater, make sure the intake line -5- to the metering pump is connected securely in the guide on the fuel delivery unit.

-- Guide the Fuel Level Sensor 2 -G169- wire out of the fuel tank.

Fig 3: Identifying Fuel Level Sensor 2 - G169- wire -4-

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-- Carefully install the fuel delivery unit and Fuel Level Sensor -G- back into the fuel tank.

-- Make sure the Fuel Level Sensor 2 -G169- wire is installed correctly:

Guide the Fuel Level Sensor 2 - G169- wire -4- next to the guide tubes -2 and 3- and above the fuel supply hose -1-.
Guide the wire -4- past the wires -5- for the Fuel Level Sensor - G- and -6- for the Transfer Fuel Pump - G6-.

-- Connect the connector -2- for the Fuel Level Sensor 2 - G169- to the locking flange -1- and make sure it is locked secure.

Fig 4: Identifying Connector

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Verification:

Fig 5: Identifying Intake Line -1-

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The locking flange guide pipes -2 and 3- must be inserted into the guides on the fuel delivery unit.
Vehicles with parking heater: the intake line -1- to the parking heater metering pump must be inserted into the guide on the fuel delivery unit.

-- Install a new dry locking flange seal -4-.

Fig 6: Identifying Dry Locking Flange Seal -4-

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CAUTION:

Risk of leaking.

When inserting sealing flange, sealing ring must not be damaged or crushed.

-- Bring the locking flange into the installation position.

The tab -1- on the locking flange must face the hole -arrow- in the retaining ring and between the tabs -2 and 3- on the fuel tank.

-- Attach the fuel lines so that they audibly latch.

-- Connect the connectors and make sure they are secure.

-- Install the right locking flange cover, refer to Figure.

-- Install the rear bench seat, refer to Removal and Installation .

-- After installing fuel delivery unit, fill vehicle with at least 5 liters (5.28 qts) of fuel.

-- Vehicles with parking heater: To vent the fuel line to the auxiliary heater metering pump, run for 10 minutes at wide open throttle.