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

Install in reverse order of removal and note the following:

NOTE:

Replace the seal after removal.

Check the fuel delivery unit for a secure fit.

-- If the vehicle has a parking heater, make sure the suction line for the parking/auxiliary heater fuel extraction is inserted correctly in the guide on the fuel delivery unit.

-- Carefully guide the fuel delivery unit into the fuel tank.

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-- Reach through the opening in the fuel tank and move the fuel delivery unit into its installation position.

The tab -1- on the fuel delivery unit must be in the groove on the baffle housing -2-.

-- Push the fuel delivery unit downward until it engages audibly into the catches on the baffle housing.

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-- Push on the fuel delivery unit again and pull on it to check if the catches -1 and 2- are engaged correctly.

-- Reach through the opening in the fuel tank and attach the suction jet line to the fuel delivery unit until it clicks into place.

NOTE:

Ignore the -arrows-.

-- Connect the connectors -1 and 2- and make sure they are securely engaged.

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-- Install a new sealing flange seal -1-. It must be dry.

Fig 1: Identifying Sealing Flange Installation Position

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CAUTION:

Risk of leaking.

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

-- Bring the sealing flange into its installation position.

The tab -2- on the sealing flange must face the hole -arrow- in the locking ring and rest between the tabs -3 and 4- on the fuel tank.

-- Firmly press on the sealing flange, position the locking ring and tighten using the : T10202 .

Fig 2: Identifying Fuel Sending Unit Wrench

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-- Attach the fuel lines until they engage audibly.

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

-- It must be ensured that at least 5 liters of fuel are in the fuel tank after installing the fuel delivery unit.

NOTE:

Do not allow the fuel pump to run when the fuel tank is empty.

-- Install the support for the luggage compartment floor. Refer to OVERVIEW - LUGGAGE COMPARTMENT FLOOR .

-- Install the bench seat / single seats. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

-- Install the sill panels. Refer to SILL PANEL, REMOVING AND INSTALLING .

-- Connect the battery while following all steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Vehicles with parking heater: to bleed the fuel line to the metering pump, allow the parking heater to run for 10 minutes at full load.