Fuel Pump: Service and Repair

FUEL DELIVERY UNIT (VEHICLES WITH ALL WHEEL DRIVE (AWD)), REMOVING AND INSTALLING

Special tools, testers and auxiliary items required




- Fuel pump wrench 3307




- Torque wrench 40-200 Nm V.A.G 1332




- Wrench 3087

REMOVING

- Read safety precautions before beginning work.
- First determine whether a coded radio is installed. In this case, determine the anti-theft coding.
- Disconnect battery Ground (GND) strap with the ignition switched off.
- Remove luggage compartment floor cover.






- Disconnect 4-pin connector as well as supply and return line from flange - arrows -.

CAUTION!
Fuel supply line is under pressure! Before loosening hose connections, place rags around the connection point. Then release pressure by carefully pulling on hose.






- Use 3087 wrench to remove locking ring.
- Pull flange and sealing ring from opening of fuel tank
- Unclip Sender for fuel gauge G at baffle housing in fuel tank and remove.






- Turn fuel delivery unit approx. 15° toward left until impact using fuel pump wrench 3307 and remove.

Note: When replacing fuel delivery unit, empty old fuel delivery unit before disposing.


INSTALLING

- Installation of the fuel delivery unit is the reverse order of removal.

Note:
^ Do not bend sender for fuel gauge when installing.
^ Coat flange seal with fuel when installing.
^ Make sure fuel lines are securely fastened.
^ Do not swap supply and return lines (return -blue-).
^ Secure fuel lines with spring type clamps.






^ Note installation position of fuel delivery unit flange: Marking on flange - 1 - must align with marking on fuel tank - 2-.
^ After installing fuel delivery unit flange, check whether supply, return and vent lines are still clipped in at fuel tank.