Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

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

Removing

• The fuel tank may be a maximum of 3/4 full.

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

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

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

- See if a coded radio is installed. If so, obtain the anti-theft code.

- Turn off the ignition and disconnect the ground cable from the battery.

- Remove the rear seat bench.

- Remove the cover from the fuel delivery unit.






- First, pull on the connector without pressing the retainer to make sure it connected securely.

- Disconnect the 5 pin connector and the fuel lines from the flange.


• The fuel or fuel lines in the fuel system can become very hot (danger of scalding)!

• In addition, the fuel system is under pressure! Before opening the system, place a cloth around the connection area and release pressure by carefully loosening the connection!

• Wear protective goggles and protective gloves when working on the fuel system!

- Release the fuel lines by pressing the lock rings.

- Disconnect the fuel lines - 1 and 2 - from the flange. Disconnecting the coupling. Refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.






- Remove lock ring using the wrench (T10202).






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

• If the fuel delivery unit is replaced, check the fuel tank for visible contamination and clean if necessary.

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

Installing

• The coupling must audibly engage when locking.

• Note the color coding when installing the coupling. Refer to => [ Coupling Allocation: ] Coupling, Disconnecting!

• Pull on the coupling to make sure it is secure.

• Disconnect the couplings. Refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.

Installation of the fuel delivery unit is the reverse of removal. Note the following:

• Do not bend the fuel level sensor when inserting the fuel delivery unit.

• Replace the seal.

• Install the fuel delivery unit seal into the fuel tank opening dry.

• Coat the seal with fuel only when installing the fuel delivery unit.

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

• Make sure the lines connections are securely fastened.

• After installing the fuel delivery unit, make sure the supply, return and ventilation lines are still attached to the fuel tank.

- Press the flange down and bring it into the 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.

- Install the lock ring, tightening specification: 110 Nm.

The rest of the installation is performed in the reverse order of removal. Note the following:

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

• Make sure the lines connections are securely fastened.

• The arrow on the cover - 2 - must point in the direction of travel.