Fuel Pump: Service and Repair

Fuel Pump, Removing and Installing

Special tools needed:







- Wrench 3217 for threaded cap nut







- Wrench 3307 for fuel pump

Removing
- Obtain radio code for radio with anti-theft coding.
- Switch off ignition and disconnect battery ground (GND) cable.
- Briefly open fuel filler cap and then close it again.
- Empty fuel tank if necessary using fuel evacuator unit VAG1433 A.


NOTE: The fuel tank may not be filled more than 1/3.


- Remove luggage compartment liner.
- Remove cover for fuel pump flange.


WARNING!
Fire hazard! Remove everything from the area that could ignite fuel or fuel vapor. fuel system is under pressure. Cover connection with rag and carefully release pressure by slowly opening the connection.







- Mark fuel return line -2- and fuel supply line -3- and disconnect from flange.
- Unclip 4-pin connector -1- and disconnect connector.







- Remove threaded cap nut with wrench 3217.
- Remove fuel pump flange and seal from fuel tank opening.
- On inside of flange disconnect connector for fuel gauge sender.
- Disconnect fuel return line on inside of flange (press release tabs).







- Insert wrench 3307 through fuel tank opening and place on inner part of fuel accumulator housing.
- Turn wrench 3307 approx. 15° to the left to stop and remove fuel pump with inner part of fuel accumulator housing.

Installing
Installation is in reverse order of removal, but do the following:


NOTE: Secure all hose connections with hose clamps identical to factory-installed clamps.


- Install inner fuel accumulator housing, fuel supply hose and fuel pump flange in fuel tank.







- Install outer fuel accumulator housing in fuel tank by aligning notch -1- on inner accumulator housing with notch -2- at outer accumulator housing.
The inner accumulator housing can be pushed down noticeably.
- Apply wrench 3307 and turn inner fuel accumulator housing with pump approx. 15° to the right to stop. Notch -1- is then aligned with marking -3- (bayonet-type connection).

NOTE: The fuel accumulator housing is shown in the illustration without fuel tank.







- When installing, turn flange to the right (direction of arrow).
- Connect fuel return line on the inside of flange.

NOTE: Lubricate O-rings with fuel before installing.


- Wrap wire for fuel gauge sensor around fuel supply line (inside fuel tank) and connect to flange.
- Seal for flange must be dry when inserted in opening of fuel tank.







- Insert flange in fuel tank.

Installation position for vehicles with all-wheel drive: -arrow 1- must be opposite -arrow 2-.


NOTE: -Arrow 3- applies for vehicles with front wheel drive.







- Tighten threaded cap nut to 60 Nm with wrench 3217.
- Connect wiring and connector.

NOTE: Check that all fuel line and hose connections are securely seated.


- After reconnecting the battery enter radio anti-theft code.
- Move power windows up to stop.
- Then operate power window closing switches again for at least 1 second to activate the automatic up-and-down run.
- Adjust time clock.
- Activate readiness code