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Recycling

Fuel escapes when fuel lines are detached. Have a suitable collecting vessel ready.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

Important!

Ensure adequate ventilation in the workbay!

Avoid skin contact (wear gloves)!

Ensure absolute cleanliness when working on the open fuel tank. Contaminants in the fuel tank can impair driving operation or may even result in vehicle breakdown!

Before starting the engine for the first time:

Top up fuel tank with at least 5 l fuel

Check transfer function of suction jet pump.

Necessary preliminary work:

Draw off fuel from fuel tank

Remove seat bench on vehicles with a 3rd row of seats

Important!

Note the following for vehicles with production dates prior to 01.07.2010.

At the tie of renewing the electric fuel pump the vehicle-sided connector must be renewed without fail.

The procedure for connecting the cables with the wiring harness is described in:

Crimping on stop parts

If the vehicle sided connector was already renewed once, the connector need not be renewed again.

For E70 without 3rd row of seats only:

Only unclip seat bench (1) as shown on the left and right and fold up in direction of arrow.

Secure seat bench on front seat (2).

If necessary, disconnect plug connection (1).

Remove cover (2).

Release nuts (1) and remove cover for sensor opening (2) from right side of fuel tank.

Disconnect plug connection (1).

Unlock the snap fastener (2) and pull off the tank ventilation line.

If necessary, unlock quick-release fastener (3) for fuel delivery line of auxiliary heater and detach.

If necessary, disconnect plug connection (4) for auxiliary heater electric fuel pump.

Completely release the rest of the torque breakaway head (1) with a screwdriver.

Remove hose clamp from clamping ring (2).

Note:

To release the hose clamp, a flexible extension can be used.

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

Installation note:

Make sure that service cover is installed in correct position.

The bulge (2) on the clamping ring must line up with the raised section (1) of the fuel tank.

The journal on the service cover (3) must line up with bulge on the clamping ring.

Hose clamp with torque breakaway head (4) always needs to be replaced.

During the tightening, press the service cap in the direction of arrow.

Tighten hose clamp until torque sheer head (4) breaks off.

Installation note:

Seal (1) must always be replaced.

Disconnect ground cable (1) towards top.

Important!

Ground cable (1) must be replaced if it has been detached once!

Carefully raise service cover.

Unclip plastic tube (1).

Unlock and disconnect snap fastener (2).

Remove the electric fuel pump.

Important!

Catch escaping fuel in a suitable collecting vessel.

No fuel is permitted to get into the passenger compartment.

With electric fuel pump removed, disconnect plug connection (1) and renew ground cable (2).