Fuel Pump: Service and Repair

Fuel Delivery Unit, Removing and Installing

Special tools, testers and auxiliary items required

• Wrench (T10202)






• Torque wrench (V.A.G 1332)






Perform the following:

Removing


Requirement:

• 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.

• Empty the fuel tank using the fuel extracting device (VAS 5190) => [ Fuel Tank, Draining ] Procedures.

• Follow all Safety Precautions. Refer to => [ Fuel Supply System, Safety Precautions ] Fuel Supply System, Safety Precautions.

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

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

- Remove the bench seat. Refer to; Seat Bench, Removing and Installing.

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






- Make sure the connector - arrow - is secure. Pull on the connector without pressing the catch. If the connector was not connected correctly, it could cause a fault.






- Pull on the connector.

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


Fuel system is under pressure!

• Wear protective goggles and protective clothing in order to avoid injury and contact with the skin.

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

- Disconnect the black supply line - 1 - and the blue return line - 2 -.






• Press the locking ring to release the fuel lines.

- Open the locking ring using the wrench (T10202).






- Remove the fuel delivery unit and seal through the opening in the fuel tank.

• When removing fuel delivery unit, be sure not to bend sender for fuel gauge.

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

Installing

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

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

• Coat the seal with fuel only for installing the fuel delivery unit on the inside.

• Do not bend the fuel level sensor (G) when inserting the fuel delivery unit.

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

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






• Tighten the locking ring to 110 Nm.

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

• Make sure the connectors and the fuel line are secure. Pull on them if necessary.

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

- Fuel System, Bleeding. Refer to => [ Fuel System, Bleeding ] Service and Repair.