Fuel Delivery Unit

Fuel Delivery Unit

If the fuel delivery unit is being replaced, then the fuel pump must be adapted to the Engine Control Module (ECM), refer to " Guided Functions" in the vehicle diagnostic tester.

Special tools, testers and auxiliary items required

• Wrench (T10202)

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

Removing

CAUTION!
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.

• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.

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

• Fuel tank and components overview, Front Wheel Drive (FWD). Refer to => [ Fuel Tank and Components Overview ] Fuel Tank and Components Overview.

• Fuel tank and components overview, All Wheel Drive (AWD). Refer to => [ Fuel Tank and Components Overview ] Fuel Tank and Components Overview.

- Drain the fuel tank using (VAS 5190) as necessary, refer to one of the following:

• FWD, refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

• AWD, refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

- Remove the rear seat bench.

- Remove the cover - 1 - with fuel pump control module (J538) - 2 - from the fuel delivery unit.





CAUTION!
The fuel supply line 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. Carefully disconnect the connection to release the pressure.

- Gently pull on the connector - A - 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 5 pin connector - A - and disconnect the fuel line - B - from flange.

• Press in the securing ring to disengage the fuel line.

- Remove the locking ring using (T10202).





- Lift the flange.

With FWD





- Disconnect the coupling - A - and remove the suction jet pump - B -. To do so, press the tabs - arrows - together.

• Press in the circlip to disengage coupling - A -.

With AWD





- Disconnect the coupling - A - to the suction jet pump.

• Press in the circlip to disengage coupling - A -.

- Remove the fuel line - B - from the fuel delivery unit. To do so, press the tabs - arrows - together.

Continuation for All Vehicles

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

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

• Follow disposal regulations.

Installing

Install the fuel level sensor (G). Refer to one of the following:

FWD, refer to => [ Fuel Level Sensor ] Fuel System Components.

AWD, refer to => [ Fuel Level Sensor ] Fuel System Components.

CAUTION!
Do not bend the fuel level sensor float arm when installing.

With FWD





- Install the delivery unit without the suction jet pump into the fuel tank.

- Install the suction jet pump - B - and connect the coupling - A -. Pull on the coupling to make sure it is securely connected.

With AWD





- Place the delivery unit in the fuel tank.

- Connect the coupling - A -. Pull on the coupling to make sure it is securely connected.

- Connect the fuel line - B - to the delivery unit.

Continuation for All





- Install the flange onto the delivery unit.

• Make sure the hoses are correctly connected.

- Pull the seal - A - over the flange and install it into the fuel tank opening.





- Lubricate the seal lightly with fuel and press the flange into the fuel tank.

- Installed position: the mark - A - points in the opposite direction of travel.





• The mark on the fuel tank is difficult to see.

- Install and tighten the locking ring using (T10202). Tightening specification: 110 Nm.

- Connect the connector - A - and the fuel line - B -.





- Pull on the coupling and connectors to make sure they are securely connected.

- Note the location of the cover - A -:





- Arrow - on the cover must point in the direction of travel.

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

• Route the fuel lines free of kinks.

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

• If the fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump, refer to "Guided Functions" in the vehicle diagnostic tester.