Fuel Pump: Service and Repair

Fuel Delivery Unit/Fuel Level Sensor

Special tools, testers and auxiliary items required

• Wrench (T10202)

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


Conditions:

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

Removing

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

• Drain 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.

• Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

- 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 is connected securely. If the connector was not connected correctly, it could cause a fault.






- Disconnect the connector - arrow -.

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


The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before disconnecting a fuel hose. Remove the hose connection carefully to release the pressure.

- Disconnect the fuel lines - 1 and 2 - from the flange. Disconnect the couplings, refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.






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






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

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

• Follow disposal regulations.

Installing

- Replace the seal.

- Install the seal into the fuel tank opening dry.

- Coat the inner side of the seal with fuel.

- When installing the 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 locking flange must lie between tabs - 1 and 3 - on the fuel tank.

• The - arrow - points in the direction of travel.

- Tighten the lock ring.

• Tightening specification: 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 connector to make sure they are fastened securely.

The rest of the installation is performed in the reverse order of removal. Note the following:

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