Note: If necessary, empty the fuel tank.
Move the front seats all the way forward. Switch off the ignition. Remove the rear seat. Unlock the latches of the cover "1" of the right connecting flange using the wedge "3409" "arrows".
Remove the sealing sleeve "1" from the cover "2" with a downward movement. Move the cover "2" back along the electrical wiring "3".
Disconnect connectors -1, 2- from the connecting flange by unlocking the connector locks.
Car with independent heater
Remove electrical connector "3" for the metering pump of the independent heater "V54" on the connecting flange. Unlock and disconnect connector "3" of the metering pump of the independent heater "V54".
All
Press the locking tab "2" upwards "arrow A", grasping it with your finger between the underbody and the fuel tank. At the same time, carefully remove the fuel pump control unit "J538" -1- from the clamp along the wiring harness "3" "arrow B". Remove the fuel pump control unit "J538" between the fuel tank and the supporting base. Put the fuel pump control unit "J538" together with the wiring harness to one side.
Disconnect fuel lines -1, 2- from the connecting flange. Unlock and disconnect the quick-release coupling.
Car with independent heater
Open the clamp and disconnect the fuel line "3" of the independent heater metering pump from the flange.
All
Note: Make sure that the connector bracket on the fuel supply module flange is not damaged when unscrewing the ring nut.
Unscrew the round nut using the T30101 (3087) key.
Pull the connecting flange "3" slightly out of the fuel tank opening. Remove the gasket "1" from the opening in the fuel tank. Carefully remove the connecting flange with the fuel line "2" through the opening in the fuel tank.
Warning! Risk of fuel leaking from the still filled fuel supply module. Place a rag underneath to collect leaking fuel.
Carefully remove the fuel delivery module with the fuel level sensor "G" through the hole in the fuel tank, rotating and rocking it slightly.
Note: When removing the fuel delivery module, be careful not to bend the float lever of the fuel level sensor "G". If it is necessary to replace the fuel delivery unit, the old delivery unit must be emptied before disposal. Check the fuel tank for contamination.
Installation
Installation in reverse order.
Note: Ensure that all components are correctly positioned. Replace a damaged sealing ring. When installing the fuel supply module, ensure that the float lever of the fuel level sensor "G" is not bent.
Install the new sealing ring "1" for the connecting flange in a dry state. Moisten the sealing ring "1" on the inside with fuel. Carefully insert the fuel supply module with the fuel level sensor "G" through the opening in the fuel tank. Press the connecting flange against the spring force and install it in the installation position.
Protrusion "2" on connecting flange "1" must be located opposite "arrow 3" on the fuel tank.
Caution! Risk of insufficiently tight seal. When installing the connecting flange, the gasket must not be damaged or pinched. Make sure that the connector bracket on the fuel delivery module flange is not damaged when tightening the ring nut.
Install the round nut and tighten it with the T30101 (3087) wrench. Insert fuel lines "1" and "2" so that they click into place with a distinct sound. If available, connect fuel line "3" of the metering pump of the independent heater "V54" to the flange. Press the fuel lines onto the fittings again, and then pull them back to check that the quick-release coupling is correctly fixed. Connect connectors "1" and "2". If available, connect electrical connector "3" of the metering pump of the independent heater "V54" to the connecting flange. Check the reliability of the fastening by pulling the connection in the opposite direction! After installing the fuel supply module, fill the car with at least 5 liters of fuel.