Fuel Delivery Unit/Fuel Level Sensor, Removing And Installing, TDI Vehicles: Installing
Install in reverse order of removal and note the following:
Replace the seal after removal.
Check the fuel delivery unit for a secure fit.
-- On market-specific version/equipment versions with a parking heater, make sure the suction line -2- to parking/auxiliary heater fuel extraction is connected correctly in the guide in the fuel delivery unit -5- and engaged -arrow-.
-- Carefully guide the fuel delivery unit into the fuel tank.
-- Reach through the opening in the fuel tank and move the fuel delivery unit into its installation position.
- The tab -3- on the fuel delivery unit must be in the groove on the baffle housing -4-.
-- Push the fuel delivery unit -1- downward until it engages audibly in the catches on the baffle housing.
-- Push the fuel delivery unit again and pull on it to check if the catches -2 and 5- are engaged correctly.
FWD Vehicles:
-- Reach in the fuel tank installation opening and connect the suction jet line -arrow- until it clicks into place. Connect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .
AWD Vehicles:
-- Reach in the fuel tank installation opening and connect the suction jet line -arrow- until it clicks into place. Connect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .
Continuation for All Vehicles:
-- Connect the connectors to the sealing flange and make sure they are secure.
- For Fuel Level Sensor -G-
- For Fuel Level Sensor 2 -G169-, present depending on the vehicle version
-- Install a new sealing flange seal -1-. It must be dry.
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 .
-- 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.
Do not allow the fuel pump to run when the fuel tank is empty.
-- Install the bench seat / single seats. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .
-- Country/Rest of World equipment versions: bleed the fuel line to the parking heater metering pump. Refer to FUEL LINE TO METERING PUMP, BLEEDING .