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.

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

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

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

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

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

Removing

- Remove the rear seat bench.

- Remove the cover for the fuel delivery unit.






- First, check that the connector - arrow - is secured in position, then pull on the connector without pressing the release to make sure the connection is secure. If the connector was not connected correctly, it could cause a fault.






- Disconnect the connector - arrow -.


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 locking ring to release the fuel lines.

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






- Pull the flange and the seal out from the opening in the fuel tank and lay them aside with the lines still attached.

- Disconnect the fuel line - 1 - for the suction jet pump through the opening of the fuel tank. Press the release button to do this.






- Disconnect the fuel line - 2 -.

- Remove the fuel delivery unit.

• 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 fuel delivery unit 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.

- Install the fuel line - 2 - until it engages audibly.






- Install the fuel line - 1 - for the suction jet pump until it engages audibly.

- Press the flange downward against the spring force and move it 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.

• 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:

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

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






Adapt the Engine Control Module (ECM) to the fuel pump if the fuel delivery unit was replaced. Refer to "Guided Functions" in the vehicle diagnostic tester.