Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Assembly Tool (T10118)

• Wrench (T10202)

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

• Fuel Extracting Device (VAS 5190)

Removing

Conditions

• The fuel tank may be a maximum of 1/2 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 using the fuel extracting device (VAS 5190) as 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.

- Remove the rear seat bench.

- Remove the cover from the fuel delivery unit.

- First, pull on the 5 pin connector - 1 - without pressing the release to make sure it is connected securely. If the connector was not connected correctly, it could cause a fault.






- Disconnect the connector - 1 -.

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

- Disconnect the connector - arrow - from the fuel pump control module using the assembly tool (T10118) and remove it.






The fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective eyewear 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 supply line - 2 - and catch any leaking fuel with a cloth.






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






- Lift the fuel delivery unit slightly and remove the seal from the fuel tank opening.

- Disconnect the fuel lines - arrows - from the delivery unit and remove the delivery unit out of the fuel tank.






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

Installing

- Connect the fuel lines - arrows -. Make sure the lines engage audibly, pull on them to make sure they are securely fastened.






- Further installation of the fuel delivery unit is the reverse of removal.

• The fuel lines are assigned to the connections.

• Pull on the connectors to make sure they are securely fastened.

• Do not bend the fuel level sensor when installing the fuel delivery unit.

• Install the fuel delivery unit seal into the fuel tank opening dry.

• Coat the seal with fuel only when installing the fuel delivery unit.

• Note the flange installed position: The tab - 1 - must face in the direction of travel. The fuel delivery unit flange can only be installed in this position.