Necessary preliminary tasks

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DRAW OFF FUEL FROM FUEL TANK
Remove rear seat bench See 5226005 REMOVING AND INSTALLING/REPLACING REAR SEAT (THROUGH-LOADING) or 5224005 REMOVING AND INSTALLING OR REPLACING REAR SEAT

Release screws (1) and remove cover (2) from right side of fuel tank.

Fig 1: Identifying Release Screws And Cover

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Disconnect plug connection (1).

Release union nut (2) and lay fuel feed line slightly to one side.

IMPORTANT: Always grip union nut (2) at hexagon (3).
Ensure that sealing faces are clean.
Catch escaping fuel.

Installation:

Tightening torque 16 12 3AZ .

Fig 2: Identifying Union Nut And Plug Connection

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Unlock quick-release fastener of vent line (4) and detach.

Lever out remainder of torque breakoff head (1) (if provided) with a screwdriver in direction of arrow.

Release hose clip of clamping ring (2) completely.

NOTE: A flexible extension can be used to release the hose clamp, e.g. special tool 00 9 252.

Press clamping ring (2) part at open end in direction of arrow and remove.

Fig 3: Identifying Clamping Ring And Breakoff Head

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Installation:

Make sure that service cover is installed in correct position.

Indentation (2) on clamping ring must line up with raised section (1) of tank.

Pin on service cover (3) must line up with indentation on clamping ring.

Hose clip with torque breakoff head (4) must always be replaced.

Tighten hose clip until torque breakoff head (4) breaks off.

Fig 4: Identifying Breakoff Head And Service Cover

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Carefully raise service cover.

Unlock and disconnect vent line and fuel feed line (1).

Unlock retaining lugs (2) on both sides of plug housing (3) and detach plug housing (3) from service cover.

Installation:

When installing the service cover, make sure that seal (4) is correctly situated in the tank opening.

Seal (4) must always be replaced.

Fig 5: Identifying Retaining Lugs And Plug Housing

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Remove service cover.

Disconnect plug connections (1) for both fuel level sensors.

Disconnect plug connection (2) for grounding cables.

IMPORTANT: The grounding cable on the filter box must not be released!

Fig 6: Identifying Plug Connection

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Unlock and disconnect fuel feed line (1).

IMPORTANT: Do not use any tools to release the fuel feed line.

Turn fuel pump in direction of arrow (counterclockwise) and remove.

Installation:

Ensure correct engagement.

Fig 7: Identifying Fuel Feed Line

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