AWD
Fuel Pump, Removing And Installing
CAUTION: To remove the Fuel Pump (FP), the fuel tank may only be filled to a maximum of 1/4. Empty fuel tank if necessary.
Recommended special tools and equipment
- 3087 wrench for tank sensor
- Fuel Pump Wrench 3307
- VAS5190 fuel siphoning device
Empty fuel tank
Observe safety precautions. Fuel Systems
Observe rules for cleanliness. Vehicle Damage Warnings
CAUTION: Observe safety precautions when disconnecting the battery.
- Disconnect battery Ground (GND) strap with the ignition switched off.
CAUTION: Secure Ground (GND) wire of V.A.G 1433 A or VAS 5190 to a blank portion of the chassis.
- Pull cone piece -2- from shaft piece -1- of VAS 5190.
- Using insulating tape, apply a mark -arrow- on hose at length a = 1,865 mm from end of suction hose.
- 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.
- Now 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.
- In this case, apply a mark -arrow- on hose at length a = 1,800 mm from end of suction hose using insulating tape. The suction hose is inserted correctly when the marking applied earlier 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.
- Drain fuel tank through fuel filler tube as much as possible.
- Carefully remove siphoning hose.
- Remove rear seat bench.
- Remove cover for right connector flange (arrows).
- Carefully disengage and disconnect electrical harness connector -1- (right side of vehicle).
- Disengage electrical harness connector -2- and lay it aside.
CAUTION: Fuel system is under pressure. Before opening system, place rags around the connection. Then release pressure by carefully loosening connection.
- Disconnect fuel supply line -arrow- from connector flange (right side of vehicle).
- Use 3087 wrench to remove locking ring.
- Pull connector flange and sealing ring from opening of fuel tank.
- Disconnect harness connector -arrow- to fuel gauge on the inside of connector flange.
- Slide suction hose for a length of dimension x = 800 mm through right opening on fuel tank to left tank chamber.
- Empty left fuel tank chamber.
Removing
- Disconnect harness connector -arrow- to fuel gauge on the inside of connector flange.
- Guide fuel pump wrench 3307 in through fuel tank opening and position on Fuel Pump (FP).
- Rotate Fuel Pump (FP) toward left approx. 15 degree to stop.
- Notch -1- aligns with marking -2- (bayonet connection)
- Remove Fuel Pump (FP).
Installing
Installation is the reverse of removal, noting the following:
- Insert Fuel Pump (FP) into baffle housing in tank so that the notch -1- at the Fuel Pump (FP) aligns with the marking -2- at the baffle housing.
- Fuel Pump (FP) can be pressed downward significantly and noticeably
- Guide fuel pump wrench 3307 in through fuel tank opening and position on Fuel Pump (FP).
- Rotate Fuel Pump (FP) toward right approx. 15 degree to stop.
- Notch -1- aligns with marking -3- (bayonet connection)
- Connect harness connector -arrow- for fuel gauge on inside of connector flange.
- Insert new, dry seal for connection flange into opening of fuel container.
- Note installation position of connector flange:
- The tab -2- on connector flange must lie between tabs -1- and -3- on fuel tank.
NOTE: Arrow points in direction of travel.
- Tighten locking ring.
- Observe safety precautions after connecting the battery.
Tightening torques
Component Nm
Locking ring for Fuel Pump (FP) 145
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".
2 - If necessary, erase DTC memory, "Mode 4: Reset/erase diagnostic data".
3 - Generate readiness code.
- End diagnosis and switch ignition off.