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

Conditions

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

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

• Drain the fuel tank using the fuel extracting device (VAS 5190) as 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 an attachments overview. Refer to => [ Fuel Tank and Attachments Overview ] Fuel Tank and Attachments Overview.

- 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 - arrow - 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 - arrow -.

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

The fuel supply line is under pressure. Always wear protective eyewear 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 lines - 1 and 2 - from the flange.






• Press the lock ring to release the fuel lines.

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






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

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

• Follow disposal regulations.

Installing

- 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 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

- Connect the supply line - 1 - (black).






- Connect the return line - 2 -. It is blue or has a blue mark.

- Connect the connector - arrow -.






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

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

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