Necessary preliminary tasks

• Draw off FUEL FROM FUEL TANK 
• Remove REAR SEAT BENCH

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

Fig 1: Identifying Fuel Tank Cover With Mounting Screws

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USA national version: 

Disconnect plug connection (1).

Unlock and detach vent lines (2).

If necessary, remove fuel line for independent heating.

Fig 2: Identifying Plug Connection And Vent Lines (USA National Version)

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ECE national-market version: 

Disconnect plug connection (1).

Unlock and detach vent line (2).

If necessary, remove fuel line for independent heating.

Fig 3: Identifying Plug Connection And Vent Line

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Release screw cap with special tool 16 1 020 and remove service cap.

Installation: 

Procedure for tightening screw cap, see next work step.

Fig 4: Releasing Screw Cap Using Special Tool (16 1 020)

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Then tighten screw cap with special tool 16 1 020 until notch (1) points to marking (2).

Fig 5: Tightening Screw Cap Using Special Tool (16 1 020)

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Carefully raise service cap (1).

Unlock and detach vent line (2).

Installation: 

Clean sealing faces and install new seal (3).

Make sure that the lever sensor moves freely before fitting the service cap.

Locating rods (4) must fit correctly in the hole of the delivery unit.

Fig 6: Identifying Service Cap And Vent Line With Seal

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Installation: 

Service cap can only be installed in one position.

When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.

Fig 7: Identifying Lug And Opening On Fuel Tank

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Unclip black return lines (1) from bracket.

Unlock and disconnect quick-release fastener (2) of fuel line.

Draw off remaining fuel from surge chamber.

Carefully lift fuel pump with fuel level sensor (3) out of fuel tank. If necessary, turn fuel pump 90° counter-clockwise and tilt towards lever sensor.

Fig 8: Identifying Black Return Lines And Quick-Release Fastener

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Removing fuel level sensor:

Carefully unlock tabs (1) and pull off fuel level sensor upwards in direction of arrow.

Disengage line (2) from holders.

Unlock plug connection (3) and detach from service cap.

Installation: 

Fuel level sensor and cable connector must audibly snap into place!

Fig 9: Identifying Plug Connection And Holders

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