Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Hose connections are secured with either spring-type or clamp-type clips.

• Replace the locking clamps with spring clamps.

• Hose clip pliers (VAS 6362) are recommended for installing spring-type clamps.

Removing

Follow all safety precautions. Refer to => [ Fuel Supply System Safety Precautions ] Fuel Supply System Safety Precautions.

Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

• The fuel tank may only be maximum of 1/2 full when removing the fuel delivery unit.

• Drain the fuel tank. Refer to => [ Fuel Tank, Draining ] Procedures.



- Remove the rear seat bench.

- Remove the flange cover - 1 - using the trim removal wedge (3409) - arrows -.






- Unlock and disconnect the connector - arrow -.






The fuel supply line is under pressure. Wear protective goggles and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

- Disconnect the fuel lines - 1 and 3 - from the flange. Disconnecting the couplings, refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.






- Remove the lock ring using the wrench (T10202) and lift the flange slightly.






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

• Drain the delivery unit before if it is going to be replaced.

• Follow all disposal regulations.

• Check the fuel tank for contamination.

Installing

Install in reverse order of removal. When doing this note the following:

- Replace the seal.

- Install the seal into the fuel tank opening dry.

- Coat the inner side of the seal with fuel.

- When installing the fuel delivery unit, be sure not to bend the fuel level sensor arm.

- Press the flange downward against the spring force and move the flange into its installed position.






• The tab - 2 - on the flange must lie between the tabs - 1 and 3 - on the fuel tank.

• The - arrow - points in the direction of travel.

- Tighten the lock ring.

Do not interchange the supply and return lines (the return line is blue or with a blue mark, the supply line is black).

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

Make sure the fuel hoses are secure.

Connections for fuel lines must engage audibly when joined.

Make sure the fuel lines are still attached to the fuel tank after installing the fuel delivery unit.

- Connect the connector - 4 -.






- Connect the couplings - 1 and 3 -.

- Pull on the couplings and connectors to make sure they are fastened securely.

• Make sure the tab - 5 - is positioned correctly.

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






Tightening Specifications