Fuel Pump: Service and Repair

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Torque wrench 40-200 Nm (VAG 1332)

Requirements

• Fuel tank may be a maximum of 3/4 full.

Removing

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

• Observe the safety precautions. Refer to --> [ Safety Precautions ] Safety Precautions.

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

- First, check whether a coded radio is installed. If necessary, obtain the anti-theft coding.

- Disconnect the battery..

- Remove the rear seat bench.

- Unclip the cover - 1 - from the fuel delivery unit. Arrow - 2 - points in direction of vehicle travel.





CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before loosening the fuel lines, place a cloth around the connection point. Then release pressure by carefully disconnecting the connection.

- Disconnect the 5 pin electrical connector - 1 -, black supply line - 2 - and blue return line - 3 -.





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

- Remove the locking ring using the (T10202).





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

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

• 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:

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

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

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

• Note installation position of the fuel delivery unit: The tab - 2 - on the fuel delivery unit must lay between the tabs - 1 - and - 3 -. - Arrow - points in direction of vehicle travel.





• Tighten the locking ring to 110 Nm.

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

• Make sure the fuel lines are seated securely.

• After installing the fuel delivery unit, check to ensure that the supply and return lines are still clipped in at the fuel tank.

• Observe the required safety precautions after connecting battery. Refer to.