Fuel Pump: Service and Repair

Fuel Delivery Unit

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

Special tools, testers and auxiliary items required

• Wrench (T10202)

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

Removing

Conditions:

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

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

- Turn off the ignition and all electric consumers.

- Remove the key.

- Remove the rear seat bench.

- Remove the cover - 1 - from the fuel delivery unit. The arrow - 2 - points in the direction of travel.






- Make sure the connector - arrow - is secure. 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 lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective goggles and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Open the connection carefully and release the pressure.

- Disconnect the fuel lines - 1 and 2 - from the fuel delivery unit flange and wipe up any fuel with a cloth. Disconnecting the couplings, refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.






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






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

• If the fuel delivery unit is being replaced, then drain it before removing it.

Installing

• Pay attention to the installed position of all the components.

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

- Replace the seal.

- Install the seal into the fuel tank opening dry.

- Coat the inner side of the seal with fuel.

- Install the fuel delivery unit. Be careful not to bend the fuel level sensor arm.

- Install the suction jet pump intake line - arrows - and lock it into place. Refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.

- Press the flange downward against the spring force and move the flange into its installed position.






• The tab - 2 - on the flange must lie between tabs - 1 and 3 - on the fuel tank.

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

- Tighten the lock ring to 110 Nm.

- Connect the connector - 1 -.






- Connect the fuel lines - 1 and 2 -.

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

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

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






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

Tightening Specifications