Fuel Delivery Unit, Removing and Installing

Fuel Delivery Unit, Removing And Installing (Engine Code 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 (approx. 45 degrees ), 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-. Carefully remove 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.

Tightening torque: 7 Nm

- Connect 4-pin connector -1-.
- Adapt (match) engine control module to throttle valve control module, Adapting components and functions.
- Generate readiness code again if DTC memory has been erased or engine control module was disconnected from permanent positive, Adapting components and functions.