Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench for Tank Sensor (T10202)

• Torque Wrench (V.A.G 1332)

CAUTION!
• Observe safety precautions when working on fuel supply. Refer to--> [ Fuel Supply System, Safety Precautions ] Fuel Supply System, Safety Precautions.

• Observe rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.

Always follow these instructions before and during work.

Removing

Conditions

• The fuel tank may be a maximum of 1/2 full.

• Empty the fuel tank if necessary using the fuel extracting device (VAS 5190). Refer to --> [ Fuel Tank, Draining ] Fuel Tank, Draining.

Procedure

CAUTION!
Electronic components could be destroyed when the battery is disconnected. Follow the required steps when disconnecting the battery!

- With the ignition switched off, disconnect ground wire - arrow - to the battery..





- Remove seat bench.

- Unclip cover - 1 - for fuel delivery unit. Arrow - 2 - points in direction of travel.





CAUTION!
• The fuel supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before loosening line connections, place rags around the connection point. Then release pressure by carefully pulling off the line.

- Disconnect connector - 1 -, black supply line - 2 - and blue return line - 3 -.





• Press in securing ring to disengage the fuel lines.

- Seal lines so that the fuel system is not contaminated by dirt etc.

- Open locking ring using wrench (T10202).





- Remove fuel delivery unit and gasket from the fuel tank opening.

• If the fuel delivery unit is to be replaced, drain old delivery unit before disposal.

• Follow disposal regulations.

Installing

Install in order of removal, noting the following:

• Locking ring tightening specification, refer to --> [ 14 Locking Ring, 110 Nm ] Fuel Tank Assembly Overview.

• When inserting fuel delivery unit into fuel tank, be sure not to bend the fuel level sensor.

• Replace fuel delivery unit gasket if damaged. Insert it in the fuel tank opening dry.

• Only coat seal with fuel when installing fuel delivery unit.

• Note installation position of fuel delivery unit flange. Refer to --> [ Installation Position of Fuel Delivery Unit Flange ] Fuel Tank Assembly Overview

• Route fuel lines kink-free.

• Do not interchange supply and return line (return line is blue, supply line is black).

• Make sure line connections are securely fastened.

- Observe notes for connecting the battery.