Fuel Pump: Service and Repair

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

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

Removing


Requirement:

• 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.

• Drain the fuel tank as necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Procedures.

• Follow all safety precautions. Refer to => [ Safety Precautions ] Fuel Supply.

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

- Turn off the ignition and all electric consumers and remove the key.

- Remove the rear bench seat.

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






- First, pull on the connector - arrow - without pressing the retainer to make sure it connected securely. If the connector was not connected correctly, it could cause a fault.






- Disconnect the connector.

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


The fuel system is under pressure!

• Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.

• Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

- Disconnect the fuel lines - 1 and 2 - from the flange.






• Press the locking ring to release the fuel lines.

- Remove the lock ring using the wrench (T10202).






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

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

• When replacing the fuel delivery unit, empty the old fuel delivery unit before disposing.

Installing

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

• Insert a new seal for the fuel delivery unit into the fuel tank opening dry.

• Only lubricate the seal with fuel on the inside when installing the fuel delivery unit.

• When inserting the fuel delivery unit into the fuel tank, be sure not to bend the fuel level sensor (G).

• Press the lock ring down and bring it into the installed position.

• Note the installed position of the fuel delivery unit: The tab - 2 - on the fuel delivery unit must lie between the tabs - 1 and 3 -. The - arrow - points in the direction of travel.






• Tighten the lock ring to 110 Nm.

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

• Make sure the electrical connector and the fuel lines are secure. Pull on them if necessary.

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