Fuel Delivery Unit, Removing and Installing

Fuel delivery unit, removing and installing
Special tools, testers and auxiliary items required





^ Spanner for union nut 3217





^ Torque wrench (40 ... 200 N m) V.A.G. 1332

Removing
Observe safety precautions.
Observe rules for cleanliness.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery ground strap.
- Fold rear seat bench forward.
- Remove cover from fuel delivery unit.
- Pull 4-pin connector as well as supply and return lines off flange.

Caution:
^ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
^ The fuel system is also under pressure! Before opening the system, place cloths around the connection. Then carefully loosen the connection to release the pressure!
^ Wear eye and hand protection when performing any type of repair work on the fuel system!





Note: Press buttons on hose couplings to disconnect fuel line connections.

- Remove union nut with spanner 3217 .
- Pull fuel delivery unit and seal out of opening in fuel tank.

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


Installing
Installation of the fuel delivery unit is performed in the reverse order.

Note:
^ Do not bend the fuel sender when installing.
^ Insert seal for flange or fuel delivery unit dry into opening of fuel tank.
^ Moisten seal with fuel only when installing flange or fuel delivery unit.
^ Ensure fuel hoses are tight.
^ After installing fuel delivery unit, check that the supply, return and breather lines are still clipped onto the fuel tank.





Note: installed position of fuel delivery unit flange. Marking on flange must align with the marking on fuel tank - arrows -.