- 1 - Fuel gauge sensor
- 2 - Fuel supply unit
- 3 - O-ring
- 4 - Fuel return pipeline. Don't go overboard
- 5 - Fuel supply pipeline. Don't go overboard
- 6 - connector
- 7 - union nut, 80Nm
- 8 - Drive jet hose
- 9 - Ejector. Vehicles with parking heater from 2/03 with parallel laying of the parking heater suction line
The fuel pump is located along with the fuel gauge in the fuel tank. All-wheel drive models, due to the need to accommodate the cardan shaft, have a fuel tank consisting of two parts. In this case, each chamber has its own fuel reserve sensor. The right chamber houses the electric fuel pump.
The illustration above shows the fuel pump for a four wheel drive gasoline engine. The description also applies to vehicles with a 1.9l diesel engine and 2.5l diesel engines from 5/02.
The fuel gauge consists of a float and a potentiometer. When the fuel level drops, the sensor float also drops. The potentiometer connected to the float increases the electrical resistance of the sensor. This reduces the voltage on the instrument panel and the fuel gauge moves in the direction «empty». For vehicles with a two-piece fuel tank, the dashboard processor calculates the total fuel amount based on the signals from the two sensors, and then outputs a signal to the fuel gauge.
Warning: Vehicles with direct injection gasoline engines have a fuel pressure regulator built into the fuel supply unit. The pressure regulator cannot be disconnected from the fuel delivery unit.
When removing the fuel pump, some fuel may leak out. Fuel vapors are poisonous and flammable. Therefore, make sure the workplace is well ventilated. Use fuel resistant gloves. Do not use open flame, fire hazard! Keep a fire extinguisher ready.
Empty the fuel tank as much as possible before removing the fuel pump and sensor. The tank should be filled no more than 2/3. For ventilation of the workplace, a radial fan can be used, the electric motor of which is located outside the air flow and has a capacity of at least 15 m3 / hour.
Front wheel drive models
Withdrawal
1. Disconnect the negative cable (-) battery.
Warning: Follow the instructions in Section Replacing the battery.
2. Sedan: Tilt the right rear seatback forward if necessary. Remove the lining of the trunk, refer to Section Removal and installation of facings (Sedan).
3. Wagon: Remove the left backrest, as well as the left lining of the trunk and the mud bath, refer to Section Removal and installation of facings (station wagon).
4. Detach the cover for the locking flange (arrows on the accompanying illustration).
5. Carefully release the 4-pin connector of the fuel gauge and fuel pump with your hand or a small screwdriver (arrow on accompanying illustration) and disconnect it.
Warning: The fuel supply line is under pressure! Before opening the hose connection, cover it with a thick cloth. Then relieve the pressure by carefully disconnecting the hose. Wear protective goggles.
6. Mark the fuel lines with a felt-tip pen (1/2) before disconnecting.
7. Disconnect the pipelines (1) submission and return (2), by squeezing the keys for fixing on the couplings. Seal the pipes with appropriate plugs or adhesive tape.
8. Models with parking heating: Additionally, disconnect the fuel supply line to the parking heater.
9. Loosen the flare nut with special tool 3217.
Warning: If the specified tool is not available, loosen the flare nut with light hammer blows through a block of wood.
Caution: Avoid sparks.
10. Remove the fuel delivery unit/reserve sensor and O-ring slightly from the fuel tank opening.
11. Move the locking flange slightly to the side with the fuel supply unit inserted in the fuel tank.
12. Release the ejector (1). To do this, grasp with your hand through the gap between the locking flange and the mounting hole in the fuel tank.
13. Remove the ejector (1) with still connected drive jet hose (2) up.
14. Disconnect the power flow hose from the ejector by pressing the release key.
15. Models with parking heating from 2/03: Disconnect the suction hose (1) for parking heating at the junction (2). To do this, press the lock key.
16. Remove the ejector.
17. Remove the fuel supply unit.
18. Drain the fuel from the fuel supply unit into a tank or other container.
19. If necessary, remove the fuel gauge. To do this, disconnect the connectors (1) And (2). Pry up with a screwdriver from the support bars (3) And (4) and remove the sensor down (arrow on accompanying illustration).
Installation
1. If necessary, insert the stock sensor into the guides on the fuel delivery unit and press up until the sensor locks into place. Lock the connector. Check the security of fastening.
2. Push the pressure hose onto the ejector connection.
3. Insert the fuel delivery unit into the tank.
4. Attach the ejector to the fuel delivery unit. To do this, grasp with your hand through the gap between the locking flange and the fuel tank mounting hole.
Caution: The ejector must lock into place clearly.
5. Insert a new locking flange seal into the fuel tank opening.
6. Check the position of the fuel supply unit: Mark on the shut-off flange (2) must match the mark on the fuel tank (1). If necessary, carefully turn the feed unit.
7. Tighten the locking flange union nut with special tool 3217 to 80Nm. You can tighten the nut with light hammer blows through a wooden block. Avoid sparks!
8. Fit the supply and return hoses according to the labels. In doing so, secure the quick couplings. The arrows on the flange indicate the direction of fluid flow.
9. Mate the 4-pin connector.
10. Connect the negative cable (-) battery.
Warning: Follow the instructions in Section Replacing the battery.
11. Further installation is performed in the reverse order of removal.
Models with all-wheel drive and front-wheel drive with a 6-cylinder diesel engine manufactured before 4/02
A key 3087 is required to unscrew the locking ring. Tightening torque 145Nm.
Caution: The locking flange may only be opened when the fuel tank is no more than 1/4 full. Otherwise, a large amount of fuel will leak out.
A fuel pump with a stock sensor 1 is installed in the right chamber. A stock sensor 2 is installed in the left tank.
Four-wheel drive vehicle, as well as a front-wheel drive vehicle with a 6-cylinder diesel engine manufactured before 4/02: The fuel pump is fixed with a bayanette lock. To remove it, it is necessary to turn it to the left by an angle of 15°with a special tool. When installing, turn accordingly to the right. There are two serifs and an arrow pointing in the direction of the bayonet lock «closed».
Visitor comments