Fuel Delivery Unit, 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.
-- If installed, make sure the suction line -6- for parking/auxiliary heater fuel extraction is inserted correctly in the guide in the baffle housing -1- 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 -arrow- on the fuel delivery unit must be in the groove on the baffle housing.
-- Push the fuel delivery unit -1- downward until it engages audibly in the catches on the baffle housing.
-- Press the fuel delivery unit back again and then pull on it to check if the retainers -2 and 3- are fastened correctly.
-- Reach in the fuel tank installation opening and connect the suction jet line -arrow- until it clicks into place. Refer to CONNECTOR COUPLINGS, DISCONNECTING .
-- Connect the connectors on the bottom of the sealing flange and make sure they are secure.
- For the Fuel Level Sensor -G-
- For the Fuel Level Sensor 2 - G169-, Fuel Level Sensor 4 - G393-
-- Install a new dry seal -1- for the sealing flange.
- 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- on the mount 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 Wrench - Fuel Sending Unit: T10202 .
-- Attach the fuel lines until they engage audibly.
-- Connect the connectors and make sure they are secure.
Risk of the fuel tank exploding when starting the fuel pump.
Severe injuries and burns are possible.
- After installing a new or completely empty fuel tank, immediately fill with at least 5 liters of fuel.
-- It must be ensured that at least five liters of fuel are in the fuel tank after installing the fuel delivery unit.
-- Install the bench seat / right single seats. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .
-- If installed, bleed the fuel line to the parking/auxiliary heater metering pump. Refer to FUEL LINE TO METERING PUMP, BLEEDING .