Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

Removing

Observe safety precautions, refer to => [ Safety Precautions ] Service Precautions.

Observe rules for cleanliness, refer to => [ Clean Working Conditions ] Clean Working Conditions.

• The fuel tank may only be maximum 1/3 full when removing the fuel delivery unit. Empty fuel tank if necessary. Refer to => [ Fuel Tank, Draining, AWD ] Fuel Tank, Draining, AWD.


Risk of destroying electrical components when battery is disconnected.

• Observe measures when disconnecting battery.

- Disconnect battery.

- Remove rear seat bench.

- Unclip catches - arrows - of right connector flange cover.





- Disconnect electrical harness connector - arrow - at locking flange.





- Mark the fuel supply line - 1 - and fuel return line - 2 -.






There is a risk of injury because the fuel is under high pressure.

• Before opening the fuel system, lay a clean cloth around the connection point and carefully loosen it, which lowers the pressure.

- Pull both lines from locking flange, by pressing the release buttons.


The fuel tank may only be maximum 1/3 full when removing the fuel delivery unit. Otherwise, a large amount of fuel will spill out.

- Remove locking ring with (T10202).





- Pull right sealing flange and seal of fuel delivery unit out from the opening in the fuel tank and lay aside with lines still attached.

- Through the fuel tank opening, separate the suction jet pipe - 1 - from suction jet pump, by pressing release button.





- Disconnect fuel delivery line - 2 - by pressing the release arrow.

- Remove the fuel delivery unit.

• When removing fuel delivery unit, be sure not to bend floater arm on the fuel level sensor (G).

• Be sure there is still some fuel inside the fuel delivery unit.

Installing

• Tightening specifications, refer to => [ Fuel Delivery Unit and Fuel Level Sensor Overview, AWD Version 2 ] Fuel Delivery Unit and Fuel Level Sensor Overview, AWD Version 2.

Installation is in reverse order of removal, note the following:

• Replace seal.

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

• Ensure fuel hoses are seated securely.

- Insert fuel delivery unit into fuel tank with locking flange set aside.

- Push the fuel delivery line - 2 - on until it engages audibly.





- Push the suction jet pipe - 1 - onto the suction jet pump until it engages audibly.

• Both of the following illustrations show the fuel delivery unit without the fuel tank.





- Insert a new dry locking flange seal into the fuel tank opening.

- Insert the guide tubes - 1 - and - 2 - of the locking flange into the guide holes - arrows - of the fuel delivery unit.

- Make sure the electrical wires - 2 - and the fuel supply lie - 3 - are routed as shown in the illustration so they do not block the lever sensor - 1 -.





- Press the locking flange down and bring it into the installation position.

• The tab - 2 - on the locking flange faces toward the - arrow marking - and must lie between tabs - 1 - and - 3 - on the fuel tank.





• - Arrow - points in direction of travel.

- Tighten locking ring.





- Install rear seat bench.

- Connect battery. Observe safety precautions after connecting battery.

Vehicles with FSI engine:

- After replacing the fuel delivery unit, a fuel pump adaptation must be performed => [ Fuel Pump, Adapting after Replacing Fuel Delivery Unit, TFSI Engine ] Fuel Pump, Adapting After Replacing Fuel Delivery Unit, TFSI Engine.