Fuel Delivery Unit, Removing and Installing

Fuel Delivery Unit, Removing and Installing


Special tools and equipment







- 3307 Key for fuel delivery unit (fuel pump)







- VAG 1332 Torque wrench (40 to 200 Nm)







- 3217 Ring nut spanner

Removing

Note safety precautions before starting work
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Remove floor cover.







- Disconnect 4-pin connector and pull supply and return lines (arrows) off flange.

WARNING!
Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.







- Remove union nut with spanner 3217.
- Pull flange and seal out of opening in fuel tank.
- Pull off fuel lines and connector on lower side of flange.
- Unclip fuel gauge sender -G- on reservoir housing and remove.







- Turn fuel delivery unit approx. 15� counter- clockwise onto stop with spanner 3307 and remove.

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

Installing


NOTE:
- Install fuel delivery unit in reverse order of removal.
- Do not bend fuel gauge sender when installing.
- Coat flange seal with fuel when installing.
- Ensure fuel hoses are seated securely.
- Do not interchange supply and return hoses (return hose -blue-).
- Secure fuel hoses with spring-type clamps.







- Note Installation position of fuel delivery unit flange: Mark on flange -1- must align with mark -2- on fuel tank.
- After installing fuel delivery unit flange, check that the supply, return and breather lines are still clipped onto the fuel tank.