Fuel Pump, Removing and Installing (FWD)

Fuel Pump, Removing And Installing: Engine Codes AUG, AWM (Front Wheel Drive)







Special tools, testers and auxiliary items required
- Ring Nut Spanner 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 if necessary.
- Read safety precautions and rules of cleanliness.

Removing
- First, check whether a coded radio is installed. If necessary, obtain the anti-theft coding.
- Switch off ignition and all electrical consumers.
- Disconnect battery Ground (GND) strap.
- 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. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.







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







- Use Ring Nut Spanner 3217 to remove union nut.
- Pull flange and seal out of the 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 Release Tool T40020 and remove.
- If necessary, siphon fuel until to upper edge of baffle housing.
- Turn Fuel Pump (FP) approx. 15 degrees toward left until impact using Fuel Pump Wrench 3307 and remove with flange.

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

Installing







- Insert Fuel Pump (FP) into baffle housing in tank so that the notch -1- at the Fuel Pump (FP) aligns with the marking - 2 at the 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.







- 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-rings for fuel return line with fuel.

- Insert wire -1- to Fuel Level Sensor on flange.
- Insert new seal for flange, dry, into opening of fuel tank and coat only the 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.
- Torque specification: 80 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 writing, return line blue writing).
- Secure fuel hoses with clamps Original parts distributor.
- 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 DTC memory of all control modules, repair all stored malfunctions, and erase DTC memory afterwards Vehicle Diagnosis, Testing and Info. System VAS 5051; Guided Fault Finding; Vehicle System Test, or Vehicle Diagnosis and Service System VAS 5052; On Board Diagnostic (OBD).