Fuel Delivery Unit In Fuel Tank, Removing and Installing

Fuel Delivery Unit In Fuel Tank, Removing And Installing

Special tools, testers and auxiliary items required







- Wrench for fuel tank sender 3087







- Fuel pump wrench 3307

Not illustrated:
- Torque wrench (40...200 Nm) V.A.G1332

Removing


NOTE:
- The fuel tank must not be more than 1/3 full.
- Empty fuel tank using fuel suction unit VAS5190 if necessary.


- Observe safety measures before performing repair work.
- Turn ignition and all electrical consumers off and remove ignition key.
- With ignition switched off disconnect battery ground strap.
- Fold rear seat bench forward.
- Remove cover from fuel delivery unit.







- Remove 4-pin connector and supply and return lines - arrows - from flange.


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.


- Seal lines so that fuel system is not contaminated by dirt etc.







- Remove locking ring with wrench 3087.
- Pull flange and seal out of opening in fuel tank.
- Unclip Sender for fuel gauge -G- at baffle housing in fuel tank and remove.







- Turn fuel delivery unit approx. 15 degrees counter-clockwise onto stop using wrench 3087 and remove with flange.


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


Installing
Installation of the fuel delivery unit is performed in the reverse order.


NOTE:
- Do not bend fuel gauge sender when installing.
- Insert seal for flange or fuel delivery unit "dry" into opening of fuel tank.
- Moisten seal with fuel only when installing flange or fuel delivery unit.
- Ensure fuel hoses are seated securely.
- Do not interchange supply and return hoses.
- Secure fuel hoses with spring-type clamps.







- Note installation position of fuel delivery unit flange: Mark on flange - 1 - must align with mark on fuel tank - 2 -.
- After installing fuel delivery unit flange, check that the supply, return and breather lines are still clipped onto the fuel tank.