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 (40-200 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

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

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

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

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

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

- Drain the fuel tank using the fuel extracting device (VAS 5190) , as necessary. Refer to one of the following:

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

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

- Remove the rear seat bench.

- Remove the cover - 1 - and the fuel pump control module - 2 - from the fuel delivery unit.






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

- Disconnect the 5 pin connector - A - and disconnect the fuel line - B - from the flange.






• Press the locking ring to unlock the fuel line.

- Remove the lock ring using the wrench (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 clip to disengage the coupling - A -.

with AWD






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

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

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

Continuation for All

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

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

• Follow disposal regulations.

Installing

Install the fuel level sensor 2, if required. Refer to => [ Fuel Level Sensor 2 G169 ] Fuel Level Sensor 2 G169.

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

with FWD






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

- Now, install the suction jet pump - B - and connect the coupling - A -. Pull on the coupling to make sure it is fastened securely.

with AWD






- Place the fuel delivery unit in the fuel tank.

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

- 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 fastened.

- Now, pull the seal - A - over the flange and insert it into the fuel tank opening.






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

- Note the installed position: The mark - A - points in the opposite direction of travel.






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

- Install the lock ring using the wrench (T10202). Tightening specification: 110 Nm.

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






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

- Note the location of the cover - A -:






The - 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:

• Make sure there are no kinks in the fuel lines when installing them.

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

• 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.