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Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section. Important: There are several types of Plastic Collar Fuel and Evaporative Emission Quick Connect Fittings used on this vehicle. • Bartholomew (1) • Q Release (2) • Squeeze to Release (3) • Sliding Retainer (4) • Push Down TI (5) The following instructions apply to all of these types of Plastic Collar Quick Connect Fittings except where indicated. 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief . Caution: Refer to Safety Glasses Caution in the Preface section. Notice: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice in the Preface section. 2. Using compressed air, blow any dirt out of the quick-connect fitting. 3. This step applies to Bartholomew style connectors ONLY. Squeeze the plastic quick connect fitting release tabs. 4. This step applies to Q Release style connectors ONLY. Release the fitting by Pushing the tab toward the other side of the slot in the fitting. 5. This step applies to Squeeze to Release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick connect fitting. 6. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move, try pressing the tab in from the opposite side. The tab will only move in one direction. 7. This step applies to the Push Down TI style connectors ONLY. Release the fitting by pressing on the tab indicated by arrow. Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.

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CAUTION: Syncro Positioning Tool T95T-12200-A (3.0L, 4.0L) or T96T-12200-A (5.0L) must be obtained prior to installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine (6007), possibly causing engine damage. CAUTION: Prior to the removal of the camshaft position sensor (CMP sensor) (12A112), set No. 1 cylinder to 0 degrees top dead center (TDC) of compression stroke. Then note the position of the camshaft position sensor electrical connector. The installation procedure requires that the electrical connector be located in the same position. Removal 1. Disconnect battery ground cable (14301). 2. Disconnect fuel charging wiring electrical connector from camshaft position sensor. 3. Remove the CMP sensor screws and camshaft position sensor from camshaft synchronizer. CAUTION: Do not move crankshaft (6303) until entire installation procedure is complete. Doing so will result in the fuel system being out of time with the engine resulting in possible emissions fault. NOTE: If camshaft synchronizer is to be removed from the cylinder block (6010), proceed with Step 4. If the camshaft synchronizer is not being removed, proceed to installation Step 8. 4. Remove hold-down clamp (12270). 5. Remove camshaft synchronizer from cylinder block. Installation 1. Attach Syncro Positioning Tool T95T-12200-A (3.0L, 4.0L) or T96T-12200-A (5.0L). Camshaft Synchronizer — 3.0L, 4.0L Camshaft Synchronizer — 5.0L 2. Align the synchronizer vane with the radial slot of the Syncro Positioning Tool T95T-12200-A (3.0L) or T96T-12200A (5.0L). 3. Rotate the tool on the synchronizer base until the tool’s boss engages the base notch. 4. Dip gear end into ESE-M2C123-A oil or equivalent to coat gear, thrust washer and lower bearing. Syncro Positioning Tool — 3.0L, 4.0L 5. CAUTION: Do not rotate crankshaft when syncro positioning tool is on the camshaft synchronizer. Armature tab will be damaged and synchronizer timing may be shifted. On 3.0L engines, install camshaft synchronizer so that drive gear engagement occurs when arrow on Syncro Positioning Tool T95T-12200-A is pointed approximately 75 degrees (3.0L), 60 degrees (4.0L) counterclockwise off the centerline of the engine. This step will locate camshaft position sensor electrical connector to the original position. Syncro Positioning Tool — 5.0L On 5.0L engines, install camshaft synchronizer into cylinder block making sure that arrow on Syncro Positioning Tool T96T-12200-A is pointing forward parallel to center line of crankshaft. This step will locate camshaft position sensor electrical connector to the pre-removal position. 6. CAUTION: If camshaft position sensor electrical connector is not positioned properly, DO NOT reposition the connector by rotating the synchronizer assembly. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer assembly and repeat Step 5. Install hold-down clamp and tighten to 19-30 Nm (14-22 lb-ft) on 3.0L, 4.0L and 23-34 Nm (17-25 lb-ft) on 5.0L. 7. Remove Syncro Positioning Tool. 8. Install CMP sensor and CMP sensor screws. Tighten to 2.5-3.5 Nm (23-30 lb-in). 9. Connect fuel charging wiring electrical connector to camshaft position sensor (CMP sensor). 10. NOTE: When battery voltage is removed from the powertrain control module (PCM) (12A650), all learned values will be cleared and reset to predetermined values. When battery voltage is restored to the PCM, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Connect battery ground cable. Camshaft Position (CMP) Sensor — 3.0L Shown, 4.0L, 5.0L Similar

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Note: There are two different fuel filter systems. In system 1, the fuel filter is located on the engine, under the engine cover. In system 2, the fuel filter is located to the left in the engine compartment, on the strut tower. Special tools, testers and auxiliary items required Suction pump VAS 5226 Remove engine cover Removing: Upper engine cover, removing and installing . Remove plug – arrow – from fuel filter housing water drain connector. Extract diesel fuel via water drain connection located on the side of the fuel filter housing – arrow – using V.A.G 1390 and V.A.G 1390/1 . Seal off oil plug again and tighten to 3 Nm. Remove line connectors for fuel lines Remove screws – arrows – along with connection lines to fuel filter housing Removing fuel filter cover: Remove screws – arrow – for fuel filter housing and remove cover Remove fuel filters – 3 – from cover – 1 – Note: Observe waste disposal regulations! Installing: Install new fuel filters – 3 – and replace seal – 2 – Install fuel filter cover – 1 – . Tighten screws – arrows – for fuel filter cover (8 Nm) Install line connectors for fuel lines. Note: Replace sealing ring between fuel filter covers and line unions for fuel hoses. Tighten bolts – arrows – to 8 Nm. Fuel system, bleeding In order to ensure engine starts immediately after changing fuel filter, fuel system must be bled with diagnostic tester. Connect diagnostic tester Switch ignition on. Select “Guided Functions” . Perform vehicle identification. Diagnostic testing unit, connecting .

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13 90 500 REPLACING TANK VENTING VALVE (S62) Interrogate fault memory of DME control unit. Switch off ignition. Location: Under intake air manifold at rear. Remove and install intake air manifold, refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S62) . Disconnect plug connection (1) on tank venting valve. Pull off tank venting valve together with rubber retainer from retainer. Press locking bracket (1). Remove hose (2). Pull off molded hose (3) from tank venting valve towards bottom. Remove tank venting valve. Installation: Apply a thin anti-friction rubber coating (e.g. petroleum jelly) to sealing surface of molded hose (3).

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WARNING: WHEN DRAINING FUEL FROM THE FUEL TANK, KEEP SPARKS, SMOKING MATERIALS, AND OPEN FLAMES AWAY FROM THE VEHICLE. WARNING: THE FUEL SYSTEM CONTAINS PRESSURIZED FUEL AFTER THE VEHICLE IS SHUT DOWN AND WILL MAINTAIN THE PRESSURE FOR A LONG PERIOD OF TIME. 1. Relieve the fuel pressure; refer to Section 310-00. 2. Disconnect the battery ground cable (14301); refer to Section 414-01. 3. Raise and support the vehicle; refer to Section 100-02. 4. Disconnect the fuel tank filler pipe hose (9047) from the fuel tank (9002). 5. Drain the fuel from the fuel tank (9002); refer to Section 310-00. 6. Disconnect the fuel tank vent tube (9A228) from fuel tank filler pipe (9034). 7. Disconnect the fuel pump electrical connector. 8. If equipped, remove fuel tank skid plate. 1. Remove the five fuel tank skid plate bolts. 2. Lower the fuel tank skid plate. 9. Position a suitable jack under the fuel tank (9002). 10. Remove the front fuel tank support strap (9092). 1. Remove the two bolts. 2. Remove the front fuel tank support strap (9092). 11. Remove the rear fuel tank support strap (9092). 1. Remove the three bolts. 2. Remove the rear fuel tank support strap. 12. Partially lower the fuel tank and disconnect the two EVAP emissions hoses. 13. Remove the two safety clips from the fuel lines. 14. Disconnect the fuel lines from the fuel pump (9350). 1. Install and push the (A) fuel line disconnect tool into the (B) female fitting. 2. Separate the male and female fitting. 15. Remove the fuel tank. 16. Remove the fuel pump. 1. Remove the fuel pump locking retaining ring (9C385). 2. Remove the fuel pump and discard the O-ring. Installation 1. Install the fuel pump (9350). 1. Install a new O-ring and fuel pump (9350). 2. Install the fuel pump locking retainer ring (9C385). 2. With a suitable jack, position the fuel tank (9002). 3. Connect the fuel lines. 4. Connect the safety clips. 5. Connect the EVAP emissions hoses.