Removal and Installation

Engine Code BPS (Plastic Fuel Tank)

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Torque wrench (40-200 Nm) (VAG 1332)

Removing

• Fuel tank may be a maximum of 3/4 full.

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

• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Description and Operation.

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

- First, check whether a coded radio is installed. If necessary, obtain the anti-theft code.

- With ignition switched off, disconnect the battery ground (GND) cable.

- Fold the rear seat bench forward.

- Remove the cover from the fuel delivery unit.

CAUTION!
Fuel system is under pressure!

• Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before loosening the line connection, place a cloth around the connection point. Then release pressure by carefully loosening the connection.

- Disconnect the 4 pin connector - 1 -, black supply line - 2 - and blue return line - 3 - from the fuel delivery unit. Press in the securing ring to disengage the lines.





- Remove the locking ring using (T10202).





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

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

• When replacing the fuel delivery unit, empty the old fuel delivery unit before disposing.

Installing

Installation of the fuel delivery unit is the reverse order of removal. When doing this note the following:

• Insert a new dry seal for the fuel delivery unit into the opening of the fuel tank.

• Only lubricate the seal with fuel on the inside when installing the fuel delivery unit.

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

• Note the installed position of the fuel delivery unit: The tab - 4 - on the fuel delivery unit must lie between tabs - 3 and 5 -. - Arrow - points in direction of travel.





• Tighten the locking ring to 110 Nm.

• Do not interchange the black supply line and blue return line (arrows on flange of fuel delivery unit).

• Make sure the fuel lines are securely fastened.

• After installing the fuel delivery unit, check whether the supply and return lines are still clipped in at the fuel tank.

• Fuel system, bleeding. Refer to => [ Fuel System, Bleeding ] Description and Operation.

• Observe the required safety precautions after connecting the battery.