FWD

Fuel Pump, Removing And Installing

CAUTION: To remove the Fuel Pump (FP), the fuel tank may only be filled to a maximum of 3/4. Empty fuel tank if necessary.

Recommended special tools and equipment







- 3217 ring nut spanner







- Fuel Pump Wrench 3307







- VAS5190 fuel siphoning device

Empty fuel tank
Observe safety precautions. Safety Precautions When Working on Fuel Supply System
Observe rules for cleanliness. Vehicle Damage Warnings

- Note and if necessary obtain radio code (for vehicles equipped with coded anti-theft radio).







- Remove cover above the battery (arrows).

NOTE: For vehicles without separate battery cover: Remove plenum chamber cover.







- Disconnect battery Ground (GND) strap (arrow) with the ignition switched off.







- Pull cone piece -2- from shaft piece -1- of VAS 5190.
- Using insulating tape, apply a mark -arrow- on hose.
- Dimension a = 985 mm
- Remove fuel filler cap from fuel filler tube.







- Screw shaft piece -1- of VAS 5190 fuel siphoning device on to fuel filler tube of fuel tank.
- Slide suction hose as far into fuel tank until the mark applied earlier -arrow- stands on shaft piece.

NOTE:







- If using a siphoning device without shaft piece, proceed principally in the same manner.
- Using insulating tape, apply a mark -arrow- on hose.
- Distance a = 1050 mm
- The suction hose -1- is inserted correctly when the marking applied earlier -arrow- stands opposite the lip of fuel filler tube.
- If the hose can only be inserted with difficulty, smear it thinly with engine oil. Never use lubricants containing silicon.

- Empty fuel tank as much as possible via fuel filler neck.
- Carefully remove siphoning hose.

Removing
- Unscrew cover for connector flange below the luggage compartment carpet.







- Carefully disengage and disconnect electrical 4-pin harness connector (arrow).

CAUTION: Fuel system is under pressure. Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.







- Mark fuel supply line -2- and fuel return line -1- and disconnect from connector flange.







- Use ring nut spanner 3217 to remove union nut.
- Pull connector flange and sealing ring from opening of fuel tank.







- Disconnect harness connector -1- for fuel gauge on inside of connector flange.

NOTE: Harness connector -2- to Fuel Pump (FP) can remain connected.

- Disconnect fuel return line -3- inside on connector flange, press release button on hose coupling to do so (arrows).







- Insert fuel pump wrench 3307 through fuel tank opening and position on inner part of baffle housing.
- Rotate inner part of baffle housing with pump toward left approx. 15 degree to stop.







- Notch -1- aligns with marking -2- (bayonet connection)
- Remove Fuel Pump (FP) with inner part of baffle housing.

Installing
Installation is the reverse of removal, noting the following:

NOTE: Secure all hose connections using hose clamps appropriate for the model type.







- Insert inner part of baffle housing into outer part of baffle housing in fuel tank so the notch -1- on inner part of baffle housing aligns with marking -2- on outer part of baffle housing.
- Inner part of baffle housing can be pressed downward significantly and noticeably.

NOTE: Baffle housing is shown without fuel tank for the sake of illustration.







- Insert fuel pump wrench 3307 through fuel tank opening and position on inner part of baffle housing.
- Rotate inner part of baffle housing with pump toward right approx. 15 to stop.







- Notch -1- aligns with marking -3- (bayonet connection)







- Connect fuel return line -2- on inside to connector flange.

NOTE:
- Always use new O-rings for the fuel return line.
- Coat O-rings for fuel return line with fuel or with lubricant.

- Insert wire -1- to sender for fuel gauge on connector flange.
- Insert new, dry seal for connection flange into opening of fuel tank.







- Insert connector flange in fuel tank, note installation position:
- Marking on connector flange -1- must align with marking on fuel tank -2-.

NOTE:
- Black arrow in illustration points in direction of travel.
- Disregard marking "TDI" on fuel tank.







- Tighten union nut for connector flange.
- Connect electrical 4-pin harness connector.







- Install fuel supply line -2- and fuel return line -1- according to the marking.

NOTE: Be sure to activate vehicle features (radio/radio-navigation system, clock, electric window regulators) according to owner's manual when the battery is re-connected.

Tightening torques

Component Nm
Union nut for Fuel Pump (FP) 80
Battery terminal to battery post 5

Final procedures
After re-connecting the voltage supply, the following work steps must be performed in the mentioned sequence:
1 - Check DTC memory "Mode 3: Check DTC memory". Diagnostic Mode 3: Check DTC Memory
2 - If necessary, erase DTC memory "Mode 4: Reset/erase diagnostic data". Diagnostic Mode 4: Reset/Erase Diagnostic Data
3 - Generate readiness code. Readiness Code, Generating

- End diagnosis and switch ignition off.