Fuel Delivery Unit

Engine Code BPR (Metal Fuel Tank)

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Torque wrench (5-50 Nm) (VAG 1331)

Removing

• Fuel tank must be empty.

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

• Read safety precautions before beginning work. Refer to => [ Safety Precautions ] Description and Operation.

- First, check whether a coded radio is installed. If necessary, obtain the anti-theft code.

- With the ignition switched off, disconnect the battery ground (GND) cable.

- Fold the rear seat bench forward.

- Remove the cover from fuel delivery unit.

- Disconnect the 4 pin connector - 1 -.





- Remove the nuts - 2 - and remove the flange - 3 -.

- Disconnect the harness connector - 1 -.





- Remove the gasket - 2 -.

CAUTION!
Fuel system is under pressure!

• Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before loosening the line connections, place a cloth around the connection point. Then release pressure by carefully loosening the line connections.

- Disconnect the connection - 1 - in line to the suction jet pump - 2 -. To do so, press the securing ring into connection.





• For the sake of illustration, the upper part of fuel tank is not shown in the illustration. The illustration is a simplified depiction of components.

- Turn the fuel delivery unit - 3 - counterclockwise (approximately 45°), remove it from the bayonet connection and set aside.

• Make sure that the filter strainer and fuel level sensor are not damaged.

- Disconnect the return line - 6 - and then the supply line - 5 - from the fuel filter.

- Guide the supply line - 1 - and return line - 2 - out of the flange cutout. Then, carefully remove the fuel delivery unit - 3 -.





• When removing the fuel delivery unit, be sure not to damage the fuel level sensor.

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

Installing

Installation of the fuel delivery unit is the reverse order of removal. When doing this note the following:

- Connect fuel lines - 1, 3 and 4 - (supply line - 3 - outward and return line - 4 - in center of fuel filter).





• Supply and return line connections must engage audibly. Check for secure fitting by pulling on the connection.

- Rotate the fuel delivery unit - 2 - in the bayonet connection clockwise until it stops.

- Install a new gasket - 2 - with the convex part facing the fuel tank.





- Place the harness connector - 1 - in the - direction of the arrow - and against the fuel level sensor behind the fuel delivery unit.

• The working area of the float must not be reduced.

- Install the flange - 3 - so that the arrow - A - points toward the rear in parallel with the longitudinal axis of the vehicle - B -.





- Tighten the nuts in a diagonal sequence - 2 -.

Tightening Specification: 7 Nm

- Connect the 4 pin connector - 1 -.

- Bleed the fuel supply system. Refer to => [ Fuel System, Bleeding ] Description and Operation.

- Connect the battery.