Fuel Delivery Unit, Removing and Installing
Fuel Delivery Unit, Removing And Installing
Installing
Special tools, testers and auxiliary items required
- Wrench for tank sensor 3087
- Fuel pump wrench 3307
- Torque wrench V.A.G 1332
- Release tool T40020
NOTE:
- To remove locking ring, fuel tank may be a maximum of 1/4 full.
- Empty right chamber of fuel tank if necessary.
- 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 rear seat bench.
- 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.
- Mark supply and return line and disconnect 4-pin connector from flange - arrows -.
- Seal lines so that fuel system is not contaminated by dirt etc.
- Remove locking ring using wrench for tank sensor 3087.
- Pull flange and seal out of opening in fuel tank.
- Disconnect connector -1- (white) and -2- (black) on inside of flange.
- If necessary, siphon fuel from right chamber of fuel tank.
- Unclip distributor piece -1- from lower part of baffle housing. To do so, press two catches, positioned one behind another -2-, toward outside - arrow A - and disconnect distributor piece - arrow B -.
NOTE: Baffle housing is shown without fuel tank for the sake of illustration.
- Disconnect fuel return line -1- from distributor piece -2-. To do so, release hose coupling of return line using release tool T40020.
- Turn Fuel Pump (FP) approx. 15 degrees toward left to stop using fuel pump wrench 3307 and remove it.
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 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.
Notch -1- aligns with marking - 3. (bayonet connection).
- Press return line -1- on distributor piece - 4. until hose coupling engages.
NOTE:
- Always use new O-rings -9-for the fuel return line.
- Coat O-rings for fuel return line with fuel.
- Connect distributor piece - 4. to baffle housing - 8. and check catch (pull against).
- Connect connectors -1- and -2- to underside of flange.
- White connector -1- for Fuel Level Sensor G to fuel supply side.
- Black connector -2- for Fuel level sensor 2 -G169- to fuel return side.
- Insert new seal for flange, dry, into opening of fuel tank and coat only inner side (equipment flange) with fuel.
- Insert lines into fuel tank and install flange.
- Marking on flange -1- must align with marking on fuel tank -2-.
- Check sealing ring for correct positioning.
- Tighten locking ring using wrench for tank sensor 3087.
- Tightening torque: 145 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).