Fuel Pump (FP) Unit, Removing and Installing
Fuel Pump (FP) Unit, Removing And Installing
Observe safety precautions.
Observe rules for cleanliness.
Requirements
- Parking brake must be engaged or else daylight driving lights will be switched on.
- Ignition switched off.
- Fuel tank must be drained
Note (Vehicles with engine code BBW).
To drain fuel tank, fuel extraction unit VAS 5190 is recommended. Contrary to operating instructions, fuel tank for this engine must not be drained via the fuel filler neck, since internal components could otherwise be damaged. Fuel tank is drained via the open flange only.
Recommended special tools and equipment
- 3217 ring nut wrench
- V.A.G1332 Torque wrench (40 to 200 Nm)
Removing
- First determine whether a coded radio is installed. If so, determine 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 harness connector as well as supply and return lines 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 flange seal of fuel pump into opening of fuel tank.
- Only coat seal with fuel when installing Fuel Pump (FP) unit.
- 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 ventilation 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.
Vehicles with engine code BBW
Recommended special tools and equipment
- V.A.G 1331 torque wrench (5 to 50 Nm)
Removing
- First determine whether a coded radio is installed. If so, determine 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 -1-.
- Remove nuts -2- and flange -3-.
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.
- Disconnect connector -1-.
- Remove sealing ring -2-.
- Drain fuel tank via flange opening, e.g. using a fuel extraction unit (VAS 5190).
- Disconnect connection -1- in line to suction jet pump -2-.
NOTE:
- To disengage, compress the buttons at the hose coupling.
- For the sake of illustration, upper part of fuel tank is not depicted in the illustration. The illustration is a simplified depiction of components.
- Turn fuel delivery unit -3- counterclockwise (approx. 45 degrees ), remove from bayonet connection and set aside.
- First disconnect return line -6- then supply line -5- from fuel filter.
- First guide supply line -1- and return line -2- out of flange opening, then carefully remove fuel delivery unit -3-.
NOTE:
- When removing fuel delivery unit, be sure not to damage sender for fuel gauge.
- When replacing fuel delivery unit, empty old fuel delivery unit before disposing.
Installing
Installation of the Fuel Pump (FP) unit is the reverse order of removal. Note the following:
- Connect connectors -1-, -3- and -4-:
- Supply line -3- to fuel filter,
- Return line -4- to fuel pressure regulator.
NOTE: Supply- and return line connections must engage audibly. Pull to check for secure seating.
- Rotate fuel delivery unit -2- on bayonet connection toward right until stop.
- Install new sealing ring -2- with bulge to fuel tank.
- Place harness connector -1- in direction of arrow against fuel gauge sender behind fuel delivery unit.
NOTE: The working area of the float must not be reduced.
- Insert flange -3-:
(Arrow -A-) on flange -3- must point toward rear in parallel to longitudinal axis of vehicle -B-.
- Tighten nuts -2- in diagonal sequence.
Tightening torque: 7 Nm
- Connect 4-pin connector -1-.
- Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data.
- Generate readiness code.