Fuel Pump: Service and Repair

Fuel Pump, Removing And Installing

Recommended special tools and equipment







- 3217 ring nut wrench







- VAG 1332 torque wrench (40 to 200 Nm)

Requirements
- Fuel tank may be a maximum of 1/2 full
- Parking brake must be engaged or else daylight driving lights will be switched on.
- Ignition switched off.

Removing
- Observe safety precautions.
- Observe rules for cleanliness.

- First determine whether a coded radio is installed. In this case, determine the anti-theft coding.
- Switch ignition off and disconnect Battery Ground (GND) strap.
- Fold rear seatback forward.
- Remove cover from Fuel Pump (FP)







- Disconnect 4-pin connector as well as supply and return line from flange (arrows).


NOTE: Depress buttons on hose connections to do so.


WARNING:
- The fuel or fuel lines in fuel system can become very hot (danger of scalding).
- In addition, the fuel system is under pressure. Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection.
- Wear protective goggles and protective gloves when working on the fuel system.


- Seal off lines so that no dirt will get into fuel system.







- Use 3217 ring nut wrench to remove union nut.
- Pull Fuel Pump (FP) and sealing ring from opening of fuel tank


NOTE: When replacing Fuel Pump (FP) unit, empty old Fuel Pump (FP) unit before disposing.


Installing

- Installation of the Fuel Pump (FP) unit is the reverse order of removal.


NOTE:
- Insert dry seal of flange/Fuel Pump (FP) into opening of fuel tank.
- Only coat seal with fuel when installing flange or Fuel Pump (FP).
- When inserting Fuel Pump (FP), be sure not to bend sender for fuel gauge.







- Note installation position of Fuel Pump (FP) flange:Marking on flange must align with marking on fuel tank (arrows).
- Make sure fuel lines are securely fastened.
- After installing Fuel Pump (FP) unit, check whether supply, return and vent lines are still clipped in at fuel tank.

- Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data.
- Generate readiness code.