Fuel Delivery Unit, Removing and Installing

Fuel delivery unit, removing and installing

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





^ 3217 Union nut spanner





^ VAG1332 Torque wrench (40...20 Nm)

Removing
Requirements
^ Fuel tank must only be a maximum 1/2 full.

Note:
^ If necessary empty fuel tank with fuel extraction unit VAS5190
^ Observe safety precautions before starting work.

WARNING: Fuel supply lines are under pressure! Before removing a hose connection wrap a cloth around the connection. Then release pressure by carefully pulling the hose off the connection.

^ Check whether a coded radio is installed. If so, obtain anti-theft coding.
^ With ignition switched off disconnect battery Ground strap.
^ Fold rear seat bench forward.
^ Remove cover from fuel delivery unit.





^ Disconnect 4-pin connector as well as supply and return lines from flange (arrows).

Note: Press buttons on hose couplings to disconnect.

^ Seal lines to avoid contamination of fuel system.





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

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

Installing
Installation of the fuel delivery unit is performed in reverse order.

Note:
^ Insert seal for fuel delivery unit flange "dry" into opening of fuel tank.
^ Moisten seal with fuel only when installing fuel delivery unit flange or fuel delivery unit.
^ When inserting fuel delivery unit be careful to ensure that the fuel gauge sender does not become bent/deformed.





^ Note installed position of flange of fuel delivery unit: Marking on flange must align with marking on fuel tank (arrows).
^ Ensure tight fit of fuel hoses.
^ After installing the fuel delivery unit, check that the supply, return and vent lines are still clipped onto the fuel tank.

^ Adapt (match) engine control module to throttle valve control module
^ If fault memory has been erased or engine control module was disconnected from permanent positive, adapt respective components to engine control module.