Fuel Delivery Unit: Installing

• Tightening Specifications FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR ASSEMBLY OVERVIEW .

Installation Is In Reverse Order Of Removal, Note The Following: 

-- Guide Suction Line -3- Out Of Fuel Tank And Connect It Until It Engages Audibly.

-- Connect Electrical Connector -2- For Fuel Level Sensor 2 -G169-.

-- Make Sure Ground (Gnd) Wire -Arrow- Is Connected Securely To Fuel Pressure Regulator Retaining Plate.

Fig 1: Identifying Fuel Filter

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-- Insert Fuel Level Sensor -G- -3- In Fuel Tank.

Fig 2: Insert fuel level sensor in fuel tank

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-- Pull Locking Flange -2- With Fuel Filter Away From Fuel Delivery Unit -1- Slightly Again -Arrow A-.

-- Bend Fuel Delivery Unit To Left Side Of Vehicle And Tilt It Into Fuel Tank -arrow B- While Being Careful Of The Fuel Level Sensor -3-.

-- Pull Locking Flange -2- With Fuel Filter Away From Fuel Delivery Unit Slightly -arrow A-.

Fig 3: Tilt Locking Flange With Fuel Filter Into Fuel Tank

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-- At The Same Time, Tilt Locking Flange With Fuel Filter Into Fuel Tank -B Arrows-, Being Especially Careful Of Retaining Plate With Ground (GND) Connection -3- And Fuel Line -4-.

-- Stretch New Sealing Ring -1- Over Locking Flange And Insert It In Groove On Fuel Tank.

-- Place Union Nut -1- On Your Left Arm And Push Locking Flange -2- Forcefully Into Installation Position With Your Left Hand -Arrow-.

Fig 4: Place Union Nut On Your Left Arm And Push Locking Flange Forcefully Into Installation Position With Your Left Hand

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• Tab -4- On Locking Flange Must Lie Between Tabs -3- And -5- On Threaded Ring.

-- Slide Union Nut -1- Off Your Left Arm Using Your Right Hand While Your Left Hand Keeps Holding Locking Flange -2- Down Firmly -arrow-.

Fig 5: Press Locking Flange Down Firmly

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-- Position Union Nut -1- With Your Right Hand So Double Ridge -5- On Ribs Is Over Lug -3- On Locking Flange (Approximately "10 O'clock" Position). This Makes Sure Union Nut Engages At Beginning Of Threads Immediately When Tightening It -4-.

-- Press Locking Flange Down Firmly With A Screwdriver -arrow-.

Fig 6: Turn Union Nut Approximately 480Degrees With Your Right Hand

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-- Turn Union Nut Approximately 480° With Your Right Hand Until Double Ridge -1- Is In Approximately "2 O'clock Position" While Keeping Locking Flange Pressed Down Firmly With Your Left Hand.

-- Tighten union nut using a union nut tool:T40068 A  .

Press The Locking Flange Down Firmly When Tightening The Union Nut So It Does Not Rotate Too.

Fig 7: Press The Locking Flange Down Firmly When Tightening The Union Nut So It Does Not Rotate Too

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• Verification: The Double Ridge -1- Must Now Be Between "7 And 8 O'clock".
  Fig 8: Double Ridge -1- Must Now Be Between "7 And 8 O'clock"

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-- Connect Fuel Lines -1- And -2-.

Fig 9: Connect Fuel Lines -1 And 2-

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-- Connect Electrical Connectors.

-- Install Right Locking Flange Cover

-- Install Rear Bench Seat. Refer To SEAT BENCH/SINGLE SEAT, REMOVING AND INSTALLING .

-- Connect Battery And Observe Safety Precautions After Connecting Battery. Refer To BATTERY, DISCONNECTING AND CONNECTING .

-- After Installing Fuel Delivery Unit, Fill Vehicle With At Least 5 Liters Of Fuel.

-- To Vent Fuel Line To Auxiliary Heater Metering Pump, Run For 10 Minutes At Wide Open Throttle (WOT).