Fuel Pump Module, Removing and Installing (FWD)

Fuel Pump Module, Removing And Installing

Special tools and test equipment







- 3217 Ring Nut Spanner







- 3307 Fuel Pump Wrench

Removing

CAUTION: Before disconnecting the battery, determine the correct coding for the anti-theft radio.







- Remove cover above battery -arrow-.

NOTE: On vehicles without separate battery cover: Remove plenum cover.







- Disconnect battery Ground (GND) strap -arrow- with ignition switched off.

Limousine:
- Remove cover for sender for fuel gauge located under liner in luggage compartment.
- If necessary; fold the right rear seat back forward.

Avant:
- Remove cover for sender for fuel gauge located under liner in luggage compartment.

All:







- Remove cover -arrow- for fuel tank sender.







- Carefully release 4-pin harness connector -arrow- and disconnect.

WARNING: Fire hazard. Fuel system is under pressure. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.







- Mark fuel pressure line -2- and return line -1- and remove from closing flange.

WARNING: The fuel tank must be empty when removing in order to reduce weight. If necessary empty fuel tank.







- Remove union nut using 3217 ring nut spanner.
- Lift closing flange and seal from tank opening.







- At inside of closing flange disconnect harness connector -1- for sender for fuel gauge.

NOTE: Harness connector -2- remains connected at fuel pump.

- Remove return line -3- at inside of closing flange while depressing release tab of hose connector.







- Insert 3307 fuel pump wrench through tank opening onto fuel pump module.
- Using 3307 fuel pump wrench, turn fuel pump module to left approx. 15 degree to stop and lift unit out.







- Notch -1- lines up with mark -2- (bayonet lock)

- Remove fuel pump with pump module housing.

Installing
Installation is the reverse of removal, however note the following:

NOTE: Replacement hose clamps must be the same type of clamp that was used in production.







- Install fuel pump module into tank with notch -1- on fuel pump module lining up with marking -2- on outside of accumulator.
- It should feel that it is possible to press fuel pump module down.

NOTE: To better show the procedure, the accumulator housing is shown without the fuel tank.







- Insert 3307 fuel pump wrench through tank opening onto fuel pump module.







- Using 3307 fuel pump wrench, turn fuel pump module approx. 15 degrees to right to stop. Notch -1- must then align with marking -3-.







- Install return line -2- on underside of closing flange.

NOTE:
- Before installing the closing flange, moisten the O-rings and the seal for the closing flange with fuel.
- Always replace O-rings for return line.

- Connect harness connector -1- for fuel gauge sender to closing flange.
- Place new closing flange seal dry into opening of fuel tank







- Insert closing flange into tank opening and note position:
- Mark on closing flange -arrow- -1- must line up with mark on fuel tank -arrow- -2-.

NOTE:
- The black -arrow- points toward the front of the vehicle.
- Do not pay attention to "TDI" marking on fuel tank







- Tighten union nut to 80 Nm (59 ft lb).
- Reconnect 4-pin harness connector







- According to previous markings, install fuel supply line -2- and return line -1-.

- With Battery re-connected, remember to activate electrical equipment (radio, clock, window switches) according to operating instructions.

- Generate readiness code.

Tightening torque

Component Nm
Battery pole 80 Nm (59 ft lb)
Union nut 5 Nm (45 in. lb)