Fuel Pump, Removing and Installing - I

Fuel Pump, Removing And Installing

Installing
Sender for fuel gauge, 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 and rules of cleanliness before beginning work.

Removing
- Check whether a coded radio is installed. If necessary, obtain radio anti-theft coding.
- Switch off ignition and all electrical consumers.
- Disconnect battery Ground (GND) strap, See Electrical Equipment, - Repair Group 27.
- Open fuel filler flap briefly and then close again.
- Remove luggage compartment floor cover.
- 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.







- Disconnect 4-pin connector and supply and return lines from flange - arrows
- Seal lines so that fuel system is not contaminated by dirt etc.







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







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

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

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







- Insert Fuel Pump (FP) into baffle housing in tank so that notch -1 at Fuel Pump (FP) aligns with marking - 2 at baffle housing.
- In this position, Fuel Pump (FP) can be pressed downward noticeably.

NOTE: Baffle housing is shown without fuel tank for the sake of illustration.







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







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







- 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.

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







- With flange in installation position, turn counter-clockwise and insert into fuel tank.
- Marking -1- on flange must align with marking - 2- on fuel tank.
- 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 Parts catalog .
- 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).