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
- Wrench 2012A
- 3087 wrench for tank sensor
- Fuel Pump Wrench 3307
- VAS5190 fuel siphoning device
Empty fuel tank
Observe safety precautions. Safety Precautions When Working on Fuel Supply System
Observe rules for cleanliness. Vehicle Damage Warnings
- Note and if necessary obtain radio code (for vehicles equipped with coded anti-theft radio).
- Remove cover above the battery (arrows).
NOTE: For vehicles without separate battery cover: Remove plenum chamber cover.
- Disconnect battery Ground (GND) strap (arrow) with the ignition switched off.
- Pull cone piece -2- from shaft piece -1- of VAS 5190.
- Using insulating tape, apply a mark -arrow- on hose.
- Dimension a = 1,085 mm
- 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.
- Slide suction hose as far into fuel tank until the mark applied earlier -arrow- stands on shaft piece.
- Insert hose into fuel filler neck up to this marking.
NOTE:
- If using a siphoning device without shaft piece, proceed principally in the same manner.
- Using insulating tape, apply a mark -arrow- on hose.
- Distance a = 1,150 mm
- The suction hose -1- is inserted correctly when the marking applied earlier -arrow- 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.
- Empty fuel tank as much as possible via fuel filler neck.
- Carefully remove siphoning hose.
- Unscrew cover for connector flange below the luggage compartment carpet.
NOTE: To do so, remove luggage compartment floor on the Avant.
- Carefully disengage and disconnect electrical 2-pin harness connector (arrow).
- Use ring nut spanner 2012 to remove union nut.
- Pull fuel level sensor 3 and seal carefully out of fuel tank opening.
- Siphon remaining fuel out of left and right fuel tank chambers through the sensor opening.
Removing
- Remove rear seat bench.
- Unscrew cover for connector flange at left beneath rear seat bench.
- Carefully disengage and disconnect electrical 4-pin harness connector (arrow).
CAUTION: Fuel system is under pressure. Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
- Mark fuel supply line -1- and fuel return line -2- and disconnect 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 both harness connectors -1- and -2- to fuel gauge on inside of connector flange.
- Unclip union piece -1- at lower part of baffle housing, to do so, carefully press union piece toward left side of vehicle and lift upward (arrow).
- Disconnect fuel return line -2- from union piece, release hose coupling for return line to do this.
NOTE: Baffle housing is shown without fuel tank for the sake of illustration.
- Insert fuel pump wrench 3307 through fuel tank opening and position on inner part of baffle housing.
- Rotate inner part of baffle housing with pump toward left approx. 15 degree to stop.
- Notch -1- aligns with marking -2- (bayonet connection)
- Remove Fuel Pump (FP) with inner part of baffle housing.
Installing
Installation is the reverse of removal, noting the following:
NOTE: Secure all hose connections using hose clamps appropriate for the model type.
- Insert inner part of baffle housing into outer part of baffle housing in fuel tank so the notch -1- on inner part of baffle housing aligns with marking -2- on outer part of baffle housing.
- Inner part of baffle housing can be pressed downward significantly and noticeably.
- Insert fuel pump wrench 3307 through fuel tank opening and position on inner part of baffle housing.
- Rotate inner part of baffle housing with pump toward right approx. 15degree to stop.
- Notch -1- aligns with marking -3- (bayonet connection)
- Insert rigid line -3- and hose line -5- into the corresponding holes of baffle housing -6-.
- Press on return line -1- on union piece -4- until hose coupling engages.
NOTE:
- Always use new O-rings -7- for the fuel return line.
- Coat O-rings for fuel return line with fuel or with lubricant.
- Clip in rigid line -3- on union piece -4-, while doing this the union piece engages itself into baffle housing -6-.
- Connect harness connectors -1- and -2- for fuel gauge on inside of connector flange.
- Insert new, dry seal for connection flange into opening of fuel tank.
- When connecting the connector flange, ensure clearance of electrical wires -2- to Fuel Pump (FP) and of return hose -1-.
- When installing, turn connector flange in direction of arrow as shown in illustration.
- Insert connector flange in fuel tank, note installation position:
- Marking on connector flange -1- must align with marking on fuel tank -2-.
NOTE: Arrow points in direction of travel.
- Tighten locking ring.
- Install supply and return hose according to marking.
- Install cover for connector flange so that the protrusion lies over the harness connector.
- Insert sensor 3 -item 2- in fuel tank as depicted in illustration.
- Floater -1- faces front left
NOTE:
- Arrow points in direction of travel.
- Fuel tank is depicted as cut-out section.
- When sliding in, turn sensor clockwise around its own axis (arrow).
NOTE: Do not bend floater arm of sender for fuel gauge when installing.
Sensor 3 is properly inserted when:
- Floater -1- and arm -2- of sensor face front left
NOTE:
- Arrow points in direction of travel.
- Fuel tank is depicted as cut-out section.
- Slide new seal for fuel level sensor 3 over connector flange of sensor.
- Insert dry seal into opening of fuel tank.
- Check the installation position of fuel level sensor 3.
- Marking on sensor -2- must align with marking on fuel tank -1-
NOTE: Arrow points in direction of travel.
- Tighten union nut for fuel level sensor 3.
NOTE: Be sure to activate vehicle features (radio/radio-navigation system, clock, electric window regulators) according to owner's manual when the battery is re-connected.
Tightening torques
Component Nm
Union nut for fuel level sensor 3 30
Locking ring for Fuel Pump (FP) 120
Battery terminal to battery post 5
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". Diagnostic Mode 3: Check DTC Memory
2 - If necessary, erase DTC memory "Mode 4: Reset/erase diagnostic data". Diagnostic Mode 4: Reset/Erase Diagnostic Data
3 - Generate readiness code. Readiness Code, Generating
- End diagnosis and switch ignition off.