Fuel Delivery Unit, Removing and Installing
Fuel delivery unit, removing and installing
Engines: AEG, APK, AQY, AVH, AZG BEJ, BER, BEV, BHP
Special tools and equipment
- 3217 Ring nut spanner
- V.A.G. 1332 Torque wrench (40 to 200 Nm)
Removing
Requirement
- Fuel tank must not be more than 1/2 full
Note:
^ Empty fuel tank with fuel extractor VAS 5190, if necessary
^ Note safety precautions before beginning work
WARNING:
^ The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
^ Always wear eye protection and wear fuel resistant gloves when disconnecting system connections.
- Check whether a coded radio is installed. If so, obtain the anti-theft coding.
- With ignition switched off, disconnect battery ground (GND) strap.
- Fold rear seat bench forward.
- Remove cover from fuel delivery unit.
- Disconnect 4- pin connector as well as supply and return lines off flange (arrow).
Note: To do this, press on hose couplings.
- Seal the lines so that the fuel system is not contaminated by dirt etc.
- Disconnect 4- pin connector as well as supply and return lines off flange (arrow).
- Remove union nut with wrench 3217.
- Pull fuel delivery unit and seal out of the opening in fuel tank.
Note: If the delivery unit is to be replaced then drain old delivery unit before disposing.
Installing
- Installation of fuel delivery unit is carried out in reverse order.
Note:
^ Insert seal for flange or fuel delivery unit dry into opening of fuel tank.
^ Moisten seal with fuel only when installing flange or fuel deliver unit.
^ Take care not to bend the fuel gauge sensor when installing fuel delivery unit.
- Note installation position of fuel delivery unit flange.
- Mark on flange must align with mark on fuel tank (arrows).
- Make sure fuel hoses are tight.
- After installing fuel delivery unit, check that the supply, return and breather lines are still clipped onto fuel tank.
- Adapt (match) engine control module to throttle valve control module, Refer to Adapting components and functions.
- Generate readiness code again if DTC memory has been erased or engine control module was disconnected from permanent positive, Refer to Adapting components and functions.
Engine: BBW
Special tools and equipment
- V.A.G. 1331 Torque wrench (5 to 50 Nm)
Removing
Requirements
- Fuel tank must be empty
Note:
^ Observe safety precautions before starting work.
^ The fuel extraction unit VAS 5190 is recommended for emptying the fuel tank. Contrary to the operating instructions the draining must not occur via the filler neck in this engine/vehicle or inner components will be damaged. Drain the fuel tank only via the opened flange.
WARNING:
^ The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
^ Always wear eye protection and wear fuel resistant gloves when disconnecting system connections.
- 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.
- Disconnect 4-pin connector -1-.
- Unscrew nuts -2- and take flange -3- off.
- Disconnect connector -1-.
- Remove seal -2-.
- Drain fuel tank via flange opening, e.g. with VAS 5190.
Note: For ease of illustration, the fuel tank upper shell is not shown. The components are shown simplified.
- Separate connector -1- on wiring to suction jet pump -2- by pressing in safety ring on connector.
- Turn fuel delivery unit -3- in counter-clockwise direction (approximately 45° ), take it out of bayonet joint and place to side.
Note: Observe that the strainer filter and the fuel gauge sender are not damaged.
- Remove fuel return hose -6- first from fuel filter and then supply hose -5-.
- Take out supply line -1- of flange cut -out and then return hose -2-, and after this carefully take out fuel supply unit -3-.
Note: When removing the fuel supply unit observe that the fuel gauge sender is not damaged.
If the fuel delivery unit is to be replaced then drain the old fuel delivery unit before disposal.
Installing
Installation of fuel delivery unit is performed in reverse order. Note the following:
- Connect connectors -1-, -3- and -4- (outer supply line -3-, return hose -4-, center of fuel retainer).
Note: The supply and return hose connectors must audibly engage. Check for correct seat by tightening.
- Turn fuel delivery unit -2- in bayonet joint to right onto limit stop.
- Install new seal -2- with bulge facing fuel tank.
- Place connector -1- in direction of arrow against fuel gauge sender behind fuel supply unit.
Note: The working area of the float must not be reduced.
- Install locking device -3- so that arrow -A- is parallel to vehicle longitudinal axle and faces backward, -B-.
- Tighten nuts -2- in a diagonal sequence.
Torque setting: 7 Nm
- Connect 4-pin connector -1-.
- Adapt (match) engine control module to throttle valve control module, Refer to Adapting components and functions.
- Generate readiness code again if DTC memory has been erased or engine control module was disconnected from permanent positive,Refer to Adapting components and functions.