Fuel Pump: Service and Repair

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

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

Removing


Requirement:

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

• After removing 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.

• Read the safety precautions before starting. Refer to => [ Safety Precautions ] Safety Precautions.

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

- Remove the rear bench seat.

- Remove the cover - arrows - from the fuel delivery unit.






- First pull on the connector - arrow - without pressing the retainer to make sure it is securely connected. 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.


The fuel system is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then release pressure by carefully disconnecting the connection.

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






• Press in the securing ring to disengage the lines.

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






- Pull delivery unit and seal out of the fuel tank opening.

• When removing the fuel delivery unit, be sure not to bend the fuel level sensor arm.

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

Installing

- Replace the seal.

- Install the seal into the opening in the fuel tank, dry.

- Lubricate the inner side of the seal with fuel.

- When installing fuel delivery unit, be sure not to bend the fuel level sensor arm.

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

• The tab - 2 - on the flange must lie between tabs - 1 and 3 - on the fuel tank.






• - Arrow - points in direction of travel.

- Install the locking ring.

• Tightening specifications: 110 Nm

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






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

- Connect the connector - arrow -.






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

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

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

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