For 1990-2009 cars

#### Special Tools

• | J 34730-1A /KM-J-34730-91 Fuel Pressure Gage

• | J 43178 /KM-37088-2A Fuel Line Disconnect Tool

• | KM-807 Closure Plugs

• | SA9805E /KM-796-A Fuel Line Separator

### Removal Procedure

Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

Important:

• | In the presence of fuel vapors or escaping fuel - observe safety regulations and national legislation. Store drained fuel in a suitable, sealable container.

• | The vehicle fuel system is designed in petrol engines as a return-free fuel system.

1. Open the hood.

• | Disconnect the ground clamp from the negative terminal.

• | Loosen the nut.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Remove the battery.
3. Reduce the fuel pressure with a pressure tester J 34730-1A /KM-J-34730-91 (1) via test connection - collect escaping fuel in suitable container - observe safety regulations and national legislation.
4. Remove the fuel supply line (1) from the fuel distributor pipe (2).

• | Remove the quick-release fitting (3) with J 43178 /KM-37088-2A .

• | Seal off with a closure plug KM-807 .

• | Remove the fuel supply line in engine compartment and uncover.

5. Remove the front frame. Refer to Front Frame Replacement .
6. Remove the 2 fuel line brackets (4) from the underbody.

• | Remove the 2 bolts.

• | Remove the fuel supply line (2).

7. Detail the fuel supply line (2) to the quick-release fitting (3) using SA9805E /KM-796-A .

Seal the fuel line with KM-807 .

8. Remove the fuel pump feed hose from the 2 dash brackets (1).

### Installation Procedure

1. Insert the fuel pump feed hose and clip into the 2 dash brackets.
2. Install the fuel pump feed hose to the intermediate fuel line.

• | Remove the closure plug KM-807 .

• | Connect the quick-release fitting. Refer to Plastic Collar Quick Connect Fitting Service .

Notice: Refer to Fastener Notice in the Preface section.

3. Install the 2 fuel line brackets to the underbody.

Install the fuel line.

Tighten
Tighten the 2 bolts.

4. Install the front frame. Refer to Front Frame Replacement .
5. Attach the fuel supply line to the fuel rail.

• | Remove the closure plug KM-807 .

• | Connect the quick-release fitting.

• | Move the fuel supply line in the engine compartment and install.

6. Install the battery.

Connect the ground clamp to the negative terminal.

Tighten
Tighten the ground clamp nut to 5 N·m (44 lb in).

7. For programming procedures, refer to Control Module References .
8. Close the hood.