Fuel delivery unit and fuel level sensor, assembly overview

1 - Fuel Level Sensor G

• Resistance values, checking → Fuel Level Sensor G , checking 
• Removing and installing → Fuel Level Sensor G , removing and installing 

2 - Fuel delivery unit

• Different versions, allocation
• Fuel pump electrical, checking → Fuel pump electrical, checking 
• Checking residual pressure →
  • 24 MULTIPORT FUEL INJECTION (MFI) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB
  • 24 - MULTIPORT FUEL INJECTION (MFI) for 2.0 LITER 4-CYL. 4V TURBO FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT
  • 24 MULTIPORT FUEL INJECTION (MFI) for 3.0 LITER 6-CYL. 5V FUEL INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN
  • 24 - FUEL INJECTION SYSTEM for 3.2 V6 4V FUEL INJECTION IGNITION, ENGINE CODE(S): BKH
  • 24 - MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 4V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BNS
  • 24 MULTIPORT FUEL INJECTION (MFI) for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BHF
• Removing and installing → Fuel delivery unit, removing and installing 

3 - Seal

• Replace
• Install dry

4 - Locking ring

• Use wrench T10202 to remove and install
• Tighten to 145 Nm

5 - Fuel supply line

• To fuel filter
• Do not kink
• Mark before removing
• To remove from locking flange, press release button on connecting piece

• Note direction of arrow (fuel supply or return) on locking flange when installing
• Clipped in on fuel tank

6 - Fuel return line

• From fuel filter
• Do not kink
• Mark before removing
• To remove from locking flange, press release button on connecting piece

• Note direction of arrow (fuel supply or return) on locking flange when installing
• Clipped in on fuel tank

7 - Electrical harness connector

• For Fuel level sensor G
• For Transfer Fuel Pump (FP) G6

8 - Suction jet pipe

• From fuel pump to suction jet pump
• To disconnect, press release button on connection piece

9 - Electrical harness connector

• For Fuel Level Sensor 2 G169

10 - Locking ring

• Use wrench T10202 to remove and install
• Tighten to 145 Nm

11 - Seal

• Replace
• Install dry

12 - Suction jet pump

• Suction jet pump, checking → Suction jet pump 
• Removing and installing → Suction jet pump, removing and installing 

13 - Fuel Level Sensor 2 G169

• Resistance values, checking → Fuel Level Sensor 2 G169 , checking 
• Removing and installing → Fuel Level Sensor 2 G169 , removing and installing 

14 - Fuel delivery line

• From suction jet pump to fuel delivery unit
• Clipped into fuel delivery unit