Fuel Tank Unit: Service and Repair

Fuel delivery unit, removing and installing
Special tools and equipment





^ 3217 Union nut spanner





^ VAG 1332 Torque wrench (40 200 Nm)

Removing
- Observe safety precautions before starting work, Refer to Fuel Delivery and Induction, Service Precautions.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Fold rear seat bench forward.
- Remove cover from fuel delivery unit.





- Disconnect 4-pin connector as well as supply and return lines from flange -arrows-.

Note: Press buttons on hose couplings to do so.

WARNING: Fuel supply lines are under pressure! Before removing from hose connections wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

- Seal lines to avoid contamination of fuel system.





- Remove union nut with spanner 3217.
- Pull fuel delivery unit and seal out of opening in fuel tank.

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

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

Note:
^ Insert seal for fuel delivery unit flange "dry" into opening of fuel tank.
^ Moisten inner edges of seal with fuel only when installing fuel delivery unit.
^ When inserting fuel delivery unit be careful to ensure that the fuel gauge sender does not become bent/deformed.





^ Note installation position of fuel delivery unit flange: The marking on flange must align with marking on fuel tank -arrows-.
^ Make sure tight fit of fuel hoses.
^ After installing fuel delivery unit, check that the supply, return and breather lines are still clipped onto fuel tank.

- Check DTC memory:
Refer to Powertrain Management
- Adapt (match) engine control module to throttle valve control module:
- Perform work sequence "Procedure after interrupting voltage supply":
- Generate readiness code again if DTC memory has been erased or engine control module separated from permanent positive supply:
Refer to Powertrain Management