Fuel Delivery Unit, Removing and Installing
(All Wheel Drive)
FUEL DELIVERY UNIT, REMOVING AND INSTALLING
Special tools, testers and auxiliary items required
^ Wrench for tank sensor 3087
^ Fuel pump wrench 3307
^ Torque wrench V.A.G 1332
^ Release tool T40020
Note:
^ To remove locking ring, fuel tank may be a maximum of 1/4 full.
^ Empty right chamber of fuel tank if necessary.
^ Read safety precautions.
REMOVING
1. Check whether a coded radio is installed. If necessary, obtain radio anti-theft coding.
2. Switch off ignition and all electrical consumers.
3. Disconnect battery Ground (GND) strap.
4. Open fuel filler flap briefly and then close again.
5. Remove rear seat bench.
6. Remove cover from fuel delivery unit.
CAUTION!
Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
7. Mark supply and return line and disconnect 4-pin connector from flange - arrows -.
8. Seal lines so that fuel system is not contaminated by dirt etc.
9. Remove locking ring using wrench for tank sensor 3087.
10. Pull flange and seal out of opening in fuel tank.
11. Disconnect connector - 1 - (white) and - 2 - (black) on inside of flange.
12. If necessary, siphon fuel from right chamber of fuel tank.
13. Unclip distributor piece - 1 - from lower part of baffle housing. To do so, press two catches, positioned one behind another - 2 - toward outside - arrow A - and disconnect distributor piece - arrow B -.
Note: Baffle housing is shown without fuel tank for the sake of illustration.
14. Disconnect fuel return line - 1 - from distributor piece - 2-. To do so, release hose coupling of return line using release tool T40020.
15. Turn Fuel Pump (FP) approx. 15° toward left to stop using fuel pump wrench 3307 and remove it.
Note: If the delivery unit is to be replaced then drain old delivery unit before disposal.
INSTALLING
1. Insert Fuel Pump (FP) into baffle housing in tank so that notch - 1 - at Fuel Pump (FP) aligns with marking - 2 - at baffle housing.
2. In this position, Fuel Pump (FP) can be pressed downward noticeably.
Note: Baffle housing is shown without fuel tank for the sake of illustration.
2. Turn Fuel Pump (FP) approx. 15° toward right until impact using fuel pump wrench 3307.
Notch - 1 - aligns with marking - 3 - (bayonet connection).
3. Press return line - 1 - on distributor piece - 4 - until hose coupling engages.
Note:
- Always use new O-rings - 9- for the fuel return line.
- Coat O-rings for fuel return line with fuel.
4. Connect distributor piece - 4 - to baffle housing - 8 - and check catch (pull against).
5. Connect connectors - 1 - and - 2 - to underside of flange.
- White connector - 1 - for Fuel Level Sensor G to fuel supply side.
- Black connector - 2 - for Fuel level sensor 2 -G169- to fuel return side.
6. Insert new seal for flange, dry, into opening of fuel tank and coat only inner side (equipment flange) with fuel.
7. Insert lines into fuel tank and install flange.
8. Marking on flange - 1 - must align with marking on fuel tank - 2 -.
9. Check sealing ring for correct positioning.
10. Tighten locking ring using wrench for tank sensor 3087.
Tightening torque 145 Nm
The rest of the assembly is basically a reverse of the disassembling sequence.
Note:
^ Do not swap supply and return lines (supply line: white lettering, return line: blue lettering).
^ Fuel lines must be secured with clamps.
^ Ensure fuel hoses are seated securely.
^ After installing fuel delivery unit flange, check that the supply, return and breather lines are still clipped onto the fuel tank.
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