Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Torque wrench 40-200 Nm (VAG 1332)

Removing

Conditions

• Fuel tank may be a maximum of 1/2 full.

• Empty the fuel tank if necessary using the (VAS 5190). Refer to --> [ Fuel Tank, Draining ] Fuel Tank, Draining.

• Fuel tank and attachments assembly overview. Refer to --> [ Fuel Tank and Attachments Assembly Overview ] Fuel Tank and Attachments Assembly Overview.

Procedure

- Read the safety precautions before beginning work. Refer to --> [ Safety Precautions ] Safety Precautions.

- Observe the rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.

- Check whether a coded radio is installed. If necessary, obtain the anti theft code.

- With the ignition off, disconnect the ground cable - arrow - from the battery..





- Remove the rear seat bench.

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





• When installing the cover - 1 - be sure to pay attention to the installed position: The arrow - 3 - points in the direction of vehicle travel.

CAUTION!
• The fuel supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before disconnecting, place a cloth around the connection point. Then release pressure by carefully disconnecting the connection.

- Disconnect the electrical connector - 1 -, black supply line - 2 - and blue return line - 3 -.





• Press in the securing ring to disengage the fuel lines.

- Seal the lines so that the fuel system is not contaminated by dirt etc.

- Remove the locking ring using the (T10202) and raise the fuel delivery unit slightly.





- Remove the fuel delivery unit and seal 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

• Tightening specifications, refer to --> [ Fuel Tank and Attachments Assembly Overview ] Fuel Tank and Attachments Assembly Overview.

Install in reverse order of removal. When doing this note the following:

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

• Replace the seal.

• Insert the seal dry.

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

• Note the installed position of the fuel delivery unit. Refer to --> [ Fuel Delivery Unit Installed Position ] Fuel Tank and Attachments Assembly Overview.

• Make sure the vent and fuel lines are not kinked.

• Do not interchange the supply and return line (return line = blue, supply line = black).

• Make sure the line connections are securely seated.

- Observe the notes after connecting the battery.