Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Torque Wrench (40_200 Nm) (V.A.G 1332)

Conditions

• The fuel tank may be a maximum of 3/4 full. This ensures the fuel level is below the fuel delivery unit flange.

Removing

• When replacing the fuel delivery unit, check the fuel tank for visible contamination and clean if necessary.

• Read the safety precautions before starting. Refer to => [ Safety Precautions ] Fuel Supply.

• Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

• Fuel tank and attachments overview. Refer to => [ Fuel Tank and Attachments Overview ] Fuel Tank and Attachments Overview.

- Drain the fuel tank as necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

- Remove the rear seat bench.

- Remove the cover - 1 - and the fuel pump control module - 2 - from the fuel delivery unit.






- First, pull on the connector - A - without pressing the retainer to make sure it is connected securely. If the connector was not connected correctly, it could cause a fault.






- Disconnect the connector.

- Check the contacts on the connector and the fuel delivery unit for damage.

The fuel supply line is under pressure. Always wear protective eye wear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

- Disconnect the fuel line - B - from the flange.






• Press the lock ring to unlock the fuel line.

- Remove the lock ring using the wrench (T10202).






- Lift the flange.

- Disconnect the coupling - A - and remove the suction jet pump - B -. To do so, squeeze the tabs - arrows - together.






• Press in the clip to disengage the coupling - A -.

- Pull the seal and fuel delivery unit out of the fuel tank opening.

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

• Follow disposal regulations.

Installing

Do not bend the fuel level sensor float arm when installing.

- Insert the delivery unit without the suction jet pump into the fuel tank.

- Now, install the suction jet pump - B - and connect the coupling - A -. Pull on the coupling to make sure it is securely fastened.






- Install the flange onto the delivery unit.






• Make sure the hoses are correctly fastened.

- Now, pull the seal - A - over the flange and insert it into the fuel tank opening.






- Coat the seal lightly with fuel and press the flange down into the fuel tank.

- Note, the installed position: The mark - A - points in the opposite direction of travel.






- Install the lock ring using the wrench (T10202). Tightening specification, see - item 21 - in the => [ Fuel Tank and Attachments Overview ] Fuel Tank and Attachments Overview.

Further installation is in the reverse order of removal. Note the following:

• The - arrow - on the cover must point in the direction of travel.






• Make sure there are no kinks in the fuel lines when installing them.

• Pull on the line connections to make sure they are secure.