Fuel Delivery Unit, Removing and Installing

Fuel Delivery Unit, Removing and Installing

Special tools, testers and auxiliary items required

• Wrench (T10202)





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





Fuel Pump (FP), removing:

CAUTION!
Requirement:

The fuel tank may be a maximum of 3/4 full on vehicles with front wheel drive and 1/3 full on vehicles with all wheel drive. This ensures the fuel level will be below the fuel delivery unit flange.

Work procedure:

• Read safety precautions before beginning work => [ Safety Precautions ] Table of Contents.

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

• Fuel tank, assembly overview.

- Empty the fuel tank using the fuel extracting device (VAS 5190) if necessary => [ Fuel Tank, Draining ] Procedures.

- Remove rear seat bench => Body Interior 72 Seats, rear.

- Remove cover - 1 - with Fuel Pump (FP) Control Module (J538) - 2 - from fuel delivery unit.





CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

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





• Press in securing ring to disengage the fuel line.

• On vehicles with auxiliary heater, harness connector and fuel line of Metering Pump (V54) must also be disconnected.

- Open locking ring using wrench (T10202).





- Lift flange.

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





• Press in circlip to disengage coupling - A -.

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

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

• Follow disposal regulations.

Fuel Delivery Unit, Installing:

CAUTION!
Do not bend Fuel Level Sensor (G) floater arm when installing.

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

- Now install suction jet pump - B - and connect coupling - A -.





- Install flange on to delivery unit.





• Make sure hoses are correctly fastened.

- Now pull sealing ring - A - over flange and insert it into fuel tank opening.





- Coat sealing ring lightly with fuel and press flange into fuel tank.

Further installation is performed in reverse order. When doing this note the following:

Marking on flange must align with marking on fuel tank - arrow -.





• Marking on fuel tank is difficult to see.

A Fuel delivery unit flange
B Flange for Fuel Level Sensor 2 (G169) (vehicle with all-wheel drive only)

- Tighten locking ring with Wrench (T10202). Tightening specifications => [ (Item 16) Locking ring, 110 Nm ] Fuel Tank, Engine Codes CBFA, CCTA and CCTB, Assembly Overview.

- Note the installation position of the cap:

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





A Fuel delivery unit cover
B Cover for Fuel Level Sensor 2 (G169) (vehicles with all-wheel drive only)

• Only coat sealing ring with fuel when installing flange

• Route fuel lines kink-free.

• Make sure lines connections are securely fastened.