Front Wheel Drive (FWD) Vehicles

Front Wheel Drive (FWD) Vehicles

Observe safety precautions. Safety Precautions When Working on Fuel Supply System
Observe rules for cleanliness. Vehicle Damage Warnings

Special tools and equipment







- 3217 ring nut wrench







- Fuel Pump Wrench 3307

Removing
- 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.

CAUTION: To remove the Fuel Pump (FP), the fuel tank may only be filled to a maximum of 1/3. Empty fuel tank if necessary.

- Unscrew cover for connector flange below the luggage compartment carpet.







- 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 -2- and fuel return line -1- and disconnect from connector flange.







- Use ring nut wrench 3217 to remove union nut.
- Pull connector flange and sealing ring from opening of fuel tank.







- Disconnect harness connector -1- for fuel gauge on inside of connector flange.

NOTE: Harness connector -2- to Fuel Pump (FP) can remain connected.

- Disconnect fuel return line -3- inside on connector flange, press release button on hose coupling to do so (arrows).







- 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.

NOTE: When replacing Fuel Pump (FP) unit, empty old Fuel Pump (FP) unit before disposing.

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.

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 right approx. 15 degree to stop.







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







- Connect fuel return line -2- on inside to connector flange.

NOTE:
- Always use new O-rings for the fuel return line.
- Coat O-rings for fuel return line with fuel or with lubricant.

- Insert wire -1- to sender for fuel gauge on connector flange.
- Insert new, dry seal for connector flange into opening of fuel tank.







- Insert connector flange in fuel tank, note installation position:
- Marking on connector flange -1- must align with marking on fuel tank -2-.

NOTE:
- Black arrow in illustration points in direction of travel.
- Disregard marking "TDI" on fuel tank.







- Tighten union nut for connector flange to 80 Nm.
- Connect electrical 4-pin harness connector.







- Install fuel supply line -2- and fuel return line -1- according to the marking.
- After connecting battery, enter anti-theft code for radio.
- Fully close power windows to stop.
- Then activate all power window switches ("up") for at least one second to activate automatic window raising/lowering.
- Set clock to correct time.
- Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data.
- Generate readiness code.

Tightening torques
Component Nm
Union nut for Fuel Pump (FP) 80
Battery terminal to battery post 5