Fuel Pump: Service and Repair

Fuel delivery module, removing and installing

Special tools, equipment, test and inspection devices; required accessories







- 3217 ring nut wrench







- VAG 1332 torque wrench (40 - 200 Nm) or equivalent

Removing
- Review safety measures before starting work.


NOTE: The battery ground strap must eventually be disconnected in the further course of work. Check whether the vehicle has a coded radio system. It may be necessary to disable the theft-deterrent feature by entering the appropriate code.


- Disconnect the battery ground strap with ignition off.
- Fold rear seat forward.
- Remove cover under seat.







- Remove 4-way connector and feed and return lines from flange -arrows-.


NOTE: Press the tabs on the hose couplings together for this.


CAUTION!
The feed line is underpressure! Place clean rags around the hose connections, then reduce the pressure by disconnecting the hose very slowly and carefully.


- Plug lines to prevent contamination of fuel system.







- Remove union nut with flare nut wrench 3217.
- Remove fuel delivery module and sealing ring through fuel tank opening.


NOTE: If the delivery module is to be replaced, empty the old delivery module before disposal.


Installing
- Install in reverse sequence.


NOTE:
- Do not bend the fuel level sensor while installing.
- For assembly, moisten the flange sealing ring with fuel.
- Make certain that the fuel hoses fit tightly.
- Fasten fuel hoses with spring band clips.
- After the flange of the fuel delivery module was installed, check that the feed, return, and vent lines are still clipped onto the fuel tank.







- Observe the flange fitting position. The marks on the flange must coincide with the marks on the fuel tank -arrows-.


- Perform basic settings.
- Read readiness code:
- If fault memory was erased or engine control module was disconnected from positive voltage supply, readiness code must be regenerated:

Fig. 1 Fitting position of the fuel delivery module flange







Markings on the sensor must agree with those on the fuel tank -arrows-.
Return line -1- with blue or with blue markings at port labeled -R-.
Black feed line -2- at port labeled -V-.


NOTE: After the flange of the fuel delivery module is installed, check that the feed, return, and vent lines are still clipped onto the fuel tank.