Right Fuel Delivery Unit With Fuel Pump
MPI Engines
Right Fuel Delivery Unit with Fuel Pump
Special tools, testers and auxiliary items required
• Wrench (T10202)
Removing
Observe safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.
Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.
• To remove the fuel delivery unit, the fuel tank may only be filled to a maximum of 1/3. Empty fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Procedures.
Observe measures when connecting battery.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
- Remove trim for luggage compartment floor.
• To remove and install fuel delivery unit, remove vehicle tool kit and spare wheel from luggage compartment. It is then possible to sit or kneel in spare wheel well.
- Unbolt cover for right locking flange - arrows -.
- Disconnect electrical connectors - 1 - and - 2 - at right locking flange.
- Mark the fuel return line - 1 - and fuel supply line - 2 -.
Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.
- Pull both lines from locking flange, by pressing the release buttons.
- Remove locking ring with Wrench (T10202).
- Pull off locking flange and remove the seal.
- Separate the electrical connectors - 1 to 3 - on the underside of the right locking flange.
• To separate the line couplings that are mentioned later in the description, pull the fuel lines out of the fuel tank opening.
• To improve clarity, the following illustration shows several components not installed.
- Through the right fuel tank opening, separate the fuel lines - 1 - and - 2 - for the left fuel delivery unit by pressing the release buttons.
3 Right fuel delivery unit with Fuel Pump (FP) (G23)
- Unclip the filling line from the front of the right fuel delivery unit - arrow -.
- Unbolt cover for left locking flange - arrows -.
- Disconnect electrical connectors - 1 - and - 2 - at left locking flange.
- Remove locking ring with Wrench (T10202).
- Pull off locking flange and remove the seal.
- Separate the electrical connectors - 1 to 3 - on the underside of the left locking flange.
- Through the left fuel tank opening, separate the suction jet pipe - 3 - from Y-piece, by pressing release button.
- Pull the suction jet pipe out toward the right fuel tank opening.
- Through the right fuel tank opening, press the release buttons - arrows - and remove the fuel delivery line - 1 - and the Fuel Level Sensor 4 (G393) - 2 -.
- Swing Fuel Level Sensor 4 (G393) aside to right.
- Press down both retaining clasps on the fuel delivery unit support - arrows -.
- Remove fuel delivery unit.
• Be aware that fuel is still in the fuel delivery unit.
Installing
• Tightening specifications. Refer to => [ Right Fuel Delivery Unit with Fuel Pump and Fuel Gauge Assembly Overview ] MPI Engines Overview.
- Before installing the fuel delivery unit, pull the retaining clasps on the support upward until it engages - arrows -.
- Carefully press the fuel delivery unit into the support until it engages audibly.
- Insert the fuel delivery line - 1 - and the Fuel Level Sensor 4 (G393) - 2 - until it engages audibly on the right fuel delivery unit.
- Through the right fuel tank opening, feed the suction jet pipe - 3 - toward the left chamber of the fuel tank.
- Push the suction jet pipe onto Y-piece until it engages audibly.
- Connect the electrical connectors - 1 to 3 - on the underside of the left locking flange.
- Install the new locking flange seal dry.
- Insert locking flange in fuel tank, note installation position:
• The tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.
- Tighten locking ring.
- Connect electrical harness connectors - 1 - and - 2 - to left locking flange.
- Fasten the cover for left locking flange - arrows -.
- Through the right fuel tank opening, press the fuel lines - 1 - and - 2 - onto the left fuel delivery unit until they engage audibly.
3 Right fuel delivery unit with Fuel Pump (FP) (G23)
- Connect the electrical connectors - 1 to 3 - on the underside of the right locking flange.
- Install the new locking flange seal dry.
- Insert locking flange in fuel tank, note installation position:
• The tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.
- Tighten locking ring.
- Install fuel supply line - 2 - and fuel return line - 1 - according to marking until they engage audibly.
- Connect electrical harness connectors - 1 - and - 2 - to right locking flange.
- Fasten the cover for right locking flange - arrows -.
- Connect battery. Observe safety precautions after connecting battery.
- After installing, fuel vehicle with at least 5 liters of fuel.