Fuel Pump: Service and Repair

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

CAUTION!
Requirement:

• Fuel tank may be a maximum of 3/4 full. This ensures the fuel level is below the fuel delivery unit flange.

Removing

• When replacing the fuel delivery unit, check the fuel tank for visible contamination and clean if necessary.

• Empty the fuel tank if necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Procedures.

• Observe safety precautions. Refer to => [ Safety Precautions ] Fuel Supply.

• Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

- Remove the rear seat bench.

- Remove the cover from the fuel delivery unit.





- First pull on the connector - arrow - without pressing the retainer to make sure it connected securely. If the connector was not connected correctly, it could cause a fault.





- Disconnect the connector.

- Check the contacts on the connector and the fuel delivery unit for damage.

CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before loosening connection wrap a cloth around the connection. Loosen the connection carefully to release the pressure.

- Remove the fuel lines - 1 and 2 - from the flange.





• Press in securing ring to disengage the fuel lines.

- Remove the locking ring using (T10202) and raise flange slightly.





- Pull delivery unit and sealing ring out of fuel tank opening.

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

• Follow disposal regulations.

Installing

- Replace seal.

- Install the dry fuel delivery unit seal into the opening in the fuel tank.

- Coat the inner side of the sealing ring with fuel.

- When installing fuel delivery unit, be sure not to bend sender for fuel gauge.

- Press the locking flange down and bring it into the installed position.





• The tab - 2 - on locking flange must lie between tabs - 1 and 2 - on the fuel tank.

• - Arrow - points in direction of travel.

- Tighten the ring.

• Tightening specifications: 110 Nm

- Connect the supply line - 1 - (black).





- Connect the return line - 2 -. It is blue or has a blue mark.

- Connect the connector - arrow -.





- Pull on the couplings and connectors to make sure they are fastened securely.

The rest of the assembly is performed in the reverse order of removal. When doing this note the following:

• Pull on the line connections to make sure they are fastened securely.

• The arrow on the cover - 2 - must point in the direction of travel.