Fuel Pump: Service and Repair

(Front Wheel Drive)

FUEL PUMP, REMOVING AND INSTALLING






Special tools, testers and auxiliary items required
- Ring nut wrench 3217
- Fuel siphoning unit VAS 5091
- Torque wrench V.A.G 1332
- Fuel pump wrench 3307

Special tools, testers and auxiliary items required




- Release tool T40020

Note:
- When removing union nut from flange, fuel tank must not be filled more than 3/4.
- Empty fuel tank.
- 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 luggage compartment floor cover.
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. Disconnect 4-pin connector and supply and return lines from flange - arrows.
8. Seal lines so that fuel system is not contaminated by dirt etc.






8. Use ring nut spanner 3217 to remove union nut.
9. Pull flange and seal out of opening in fuel tank.






10. Disconnect connector for fuel gauge - 1 - on inside of flange.

Note: Connector - 2- to Fuel Pump (FP) can remain connected.

11. Disconnect fuel return line - 3 - at inside of flange using releasing tool T40020 and remove.
12. If necessary, siphon fuel until it reaches upper edge of baffle housing.
13. Using fuel pump wrench 3307 turn Fuel Pump (FP) approx. 15° toward left until impact and remove with flange.

Note: If the delivery unit is to be replaced then drain the 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.






3. Turn Fuel Pump (FP) approx. 15° toward right until impact using fuel pump wrench 3307.






4. Check that notch - 1 - aligns with marking - 3 - (bayonet connection).






5. Connect fuel return line - 2 - on inside to flange.

Note:
- Always use a new O-ring for the fuel return line.
- Coat O-ring for fuel return line with fuel.

6. Insert wire - 1 - to sender for fuel gauge on flange.
7. Insert new seal for flange, dry, into opening of fuel tank and coat only inner side (equipment flange) with fuel.






8. With flange in installation position, turn counter-clockwise and insert into fuel tank.
9. Marking - 1 - on flange must align with marking - 2 - on fuel tank.
10. Tighten union nut.
Tightening torque 60 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.

Check Diagnostic Trouble Code (DTC) memory of all control modules, repair all stored malfunctions, and erase DTC memory Vehicle Diagnosis, Testing and Information System VAS 5051; Guided Fault Finding; Vehicle System Test, or Vehicle Diagnosis and Service Information System VAS 5052; On Board Diagnostic (OBD).