Transfer Fuel Pump - G6-, REMOVING AND INSTALLING, VEHICLES WITH 3.0L (V6)/4.2L (V8) ENGINES FROM 06/2010: Removing

WARNING: This page is about a different variant/trim than selected.

Follow all safety precautions, refer to WORKING ON FUEL SYSTEM .

Follow the guidelines for clean working conditions, refer to CLEAN WORKING CONDITIONS .

The fuel tank must be completely empty to remove the fuel delivery unit. Procedure to empty the fuel tank, refer to FUEL TANK, DRAINING .

-- Remove the right rear single seat in the second row of seats, refer to Seat Frames .

Fig 1: Cut The Floor Covering Along The Perforation

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WARNING:

Risk of injury.

Wear safety gloves

-- Cut the floor covering along the perforation -arrows- on the right side with a carpet knife -1-.

-- Fold carpet cut-out to side in direction of -arrow-.

Fig 2: Identifying Locking Flange Cover - Tightening Specifications

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-- Remove nuts -1 to 4- and remove right locking flange cover.

-- Disconnect the connector -4- on the right locking flange.

Fig 3: Locking Flange Connectors

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-- If equipped, disconnect the connector -3- on the locking flange.

NOTE:

Place a clean cloth under the separating location to catch any fuel that may leak out.

WARNING:

Very hot fuel can burn your skin.

In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

There is a risk of injury because the fuel is under pressure.

To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

-- Disconnect fuel lines -1 and 2-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Vehicles with parking heater: Disconnect the fuel line to the parking heater. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Remove locking ring using the Wrench - Fuel Sending UnitT10202.

Fig 4: Identifying Removal Of Locking Ring With T10202

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-- Pull the locking flange -4- out of the fuel tank slightly and remove the seal -1-.

Fig 5: Fuel Delivery Unit Components Location

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-- Disconnect the connectors -2 and 3- on the bottom of the locking flange.

-- Remove the fuel line -5- from the fuel tank and disconnect it. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Reach into the opening in the fuel tank and disconnect the auxiliary heater supply line -2- from the fuel delivery unit by pressing the releases.

Fig 6: Fuel Delivery Unit Lines Location

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-- Reach into the fuel tank opening and disconnect the return line -1- from the fuel delivery unit. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Remove the locking flange.

-- Reach into the fuel tank opening and press the releases -arrows- and disconnect the supply line -1- from the fuel delivery unit.

Fig 7: Fuel Delivery Unit Bayonet Connection Location

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-- Reach into the fuel tank opening and disconnect the suction jet line -2- to the suction jet pump. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Reach into the opening in the fuel tank and turn the fuel delivery unit -1- counterclockwise 15° -arrow- to release (bayonet connection).

Fig 8: Identifying Fuel Delivery Unit -1-, Notch -3-, And Retaining Ring Tab -4-

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NOTE:

The fuel delivery unit is illustrated without the fuel tank.

The notch -3- on the fuel delivery unit then aligns with the retaining ring tab -4-.

-- Remove the fuel line out of the opening in the fuel tank and remove the fuel delivery unit upward.

NOTE:

Be sure there is still some fuel inside the fuel delivery unit.