Fuel Tank Unit: Service and Repair

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Union nut tool (3217 )

• Torque wrench (V.A.G 1332)





Observe safety precautions => [ Safety Precautions ] .

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

Removing

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

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

- To remove the fuel delivery unit, the fuel tank may only be filled to a maximum of 3/4. Empty fuel tank => [ Fuel Tank, Draining ] , if necessary.

- Fold rear seat bench forward.

- Remove cover from fuel delivery unit.

CAUTION!
• The fuel or fuel lines in fuel system can become very hot (danger of scalding)!

• In addition, the fuel system is under pressure! Before opening the system, place cloths around the connection area and release pressure by carefully loosening the connection!

• Wear protective goggles and protective gloves when working on the fuel system!

- Disconnect the 4 pin connector as well as the supply and return line from the fuel delivery unit.

• Press in securing ring to disengage the lines.

- Remove the ring nut using the (3217) ring nut spanner.





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

• When replacing fuel delivery unit, empty old fuel delivery unit before disposing.

Installing

- Installation of the fuel delivery unit is the reverse order of removal.

• Do not bend fuel gauge sender when installing.

• Insert dry new sealing ring of fuel delivery unit into opening of fuel tank.

• Only coat seal on inside with fuel when installing Fuel Pump (FP).

• Note installation position of fuel delivery unit: Marking on fuel delivery unit must align with marking on fuel tank - arrows -.





• After installation, check fuel delivery unit to make sure the fuel supply line - 2 - and the fuel return line- 1 - are still clipped onto fuel tank.

- Connect battery