Fuel Tank Unit: Service and Repair

Fuel Delivery Unit, Removing And Installing

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required







- V.A.G 1332 Torque wrench (40 to 200 Nm)







- 3217 Ring nut spanner

Removing
- Note safety precautions before starting work.
- First check whether a coded radio is installed. If this is the case obtain the anti-theft coding.
- With the ignition switched off disconnect battery Ground strap.
- Remove cover under bench seat.
- Pull 4-pin connector as well as supply and return pipes off flange.


NOTE: Press buttons on hose couplings to do this.


WARNING!
Fuel supply pipes are underpressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.







- Remove union nut with spanner 3217.
- Pull fuel delivery unit and seal out of the opening in fuel tank.


NOTE: If the delivery unit is to be replaced then drain old delivery unit before disposal.


Installing
- Installing the fuel delivery unit is carried out in the reverse order.


NOTE:
- When inserting the fuel delivery unit make sure that the fuel gauge sender is not bent.
- Insert flange seal of fuel pump into the opening in dry condition.
- Only coat seal with fuel for installing fuel pump.
- Make sure fuel hoses are seated securely.







- Note installation position of fuel delivery unit flange: The marking on flange must align with marking on fuel tank -arrows-.
- After installing fuel delivery unit, check that the supply, return and vent pipes are still clipped onto fuel tank.


- Perform the work sequence "Procedure after voltage supply open circuit".