Fuel Delivery Unit, Removing and Installing

Fuel Delivery Unit, Removing And Installing







Special tools, testers and auxiliary items required
- Ring nut wrench 3217
- Fuel pump wrench 3307
- Torque wrench (40 to 200 Nm) V.A.G 1332

Removing

NOTE:
- The fuel tank must not be more than 1/4 full.
- Empty fuel tank if necessary.
- Observe safety precautions before performing repair work.

- Check whether a coded radio is installed. If necessary, obtain anti-theft coding.
- Disconnect battery Ground (GND) strap with ignition switched off.
- Remove luggage compartment floor cover.
- Pull supply line - 1 - and return line - 2 -, as well as 4-pin connector - 3 - off of flange.







- Separate connector - 4 -.

CAUTION: Fuel supply lines are under pressure. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.







- Use Ring nut spanner 3217 to remove union nut.
- Pull flange and seal out of opening in fuel tank.







- Pull off fuel return line - 2 - and connector for fuel gauge sender on underside of flange - 1 -.







- Pull off connection piece of return hose at inner part of baffle housing in direction of arrow.







- While pressing retaining tab, pull out Sender for fuel gauge -G- from baffle housing in fuel tank - arrows -.







- Press release buttons - arrows - and separate fuel hose at Y-fitting.







- Turn fuel delivery unit approx. 15 degrees counter-clockwise onto stop using Fuel pump wrench 3307 and remove with flange.

NOTE: If the delivery unit is to be replaced then drain old delivery unit before disposal.

Installing







- Insert fuel pump into baffle housing in fuel tank so that notch - 1 - at fuel pump aligns with marking - 2 - at baffle housing.

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







- Turn fuel delivery unit approx. 15 degrees clockwise onto stop using fuel pump wrench 3307.







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







- Push fuel hose onto Y-fitting and push together until retaining tabs - arrows - engage.
- Place Y-fitting with fuel hoses into fuel tank toward right rear.

NOTE: Make sure that the fuel hose from the baffle housing to the Y-fitting is hooked into the retainer at the outer part of the baffle housing.

- Clip in fuel return line at inner part of baffle housing.
- Insert fuel gauge sender in guide at baffle housing and press down until it engages.
- Reconnect fuel gauge sender connector and fuel return line to flange.

NOTE:
- Insert dry seal of fuel pump into opening of fuel tank.
- Only coat seal with fuel when installing Fuel Pump (FP).

- With flange in installation position, turn clockwise and insert into fuel tank.







- Check that marking on flange aligns with marking on fuel tank - arrow -.
- Tighten union nut.Tightening torque: 80 Nm

The rest of the assembly is basically a reverse of the disassembling sequence.

NOTE:
- Do not switch supply and return hoses (return line -blue- or with blue markings).
- Ensure fuel hoses are seated securely.