Fuel Delivery Unit

Fuel Delivery Unit, Removing And Installing

Special tools, testers and auxiliary items required







- Wrench T10202







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

Removing:
- Fuel tank may be a maximum of 3/4 full.

NOTE:
- Empty the fuel tank if necessary using fuel extraction unit VAS 5190 Fuel tank, emptying.
- Read safety precautions before beginning work.
- Observe rules for cleanliness.

- Remove seat bench.







- Remove cover -1- with Fuel Pump (FP) Control Module -2- from fuel delivery unit.

CAUTION: Fuel supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.







- Remove connector -1- and fuel lines -2 and 3- from flange.

NOTE:
- Press in securing ring to disengage the fuel lines.
- On vehicles with auxiliary heater, harness connector and fuel line of Metering Pump V54 must also be disconnected.







- Open locking ring using wrench T10202 and raise flange slightly.
- Pull delivery unit and sealing ring out of fuel tank opening.

NOTE:
- When removing fuel delivery unit, be sure not to bend fuel gauge sensor.
- If the delivery unit is to be replaced then drain old delivery unit before disposal.

Installing:
Installation of the fuel delivery unit is in reverse order of removal. When doing this, note the following:
- When inserting fuel delivery unit into fuel tank, be sure not to bend fuel gauge sensor.
- Insert dry sealing ring of fuel delivery unit into opening of fuel tank.
- Only coat seal with fuel when installing fuel delivery unit.
- Note installation position of fuel delivery unit flange
- Do not interchange supply and return lines (return line is blue or has blue marking, supply line is black).
- Observe installation location of auxiliary heater fuel extraction line.
- Make sure lines connections are securely fastened.
- If fuel delivery unit was replaced, adapt Engine Control Module to Fuel Pump (FP) "Guided Functions".







Installation position of fuel delivery unit flange
Marking -3- on sensor points in opposite direction of travel.
Blue or blue-marked return line -1-.
Black supply line -2-