Removing and installing fuel delivery unit, front-wheel drive — VW

Removing and installing fuel delivery unit, front-wheel drive
Special tools and workshop equipment required
Union nut key
3217
Torque wrench (40... 200 Nm)
V.A.G 1332
Removing
Fuel tank must not be more than
3
/
4
full.
If necessary, drain fuel tank using
fuel extractor
VAS 5190
Chapter
.
Disconnect earth cable at
battery
with ignition switched off
Rep. gr.
27
Disconnecting and connecting battery
.
Remove fuel tank
Chapter
.
WARNING
The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!
Wear eye and hand protection when performing any type of repair work on the fuel system!
Release connector
arrow
and pull it off flange
1
.
Remove fuel lines
1
and
2
Chapter
“
Separating plug-in connectors
”
.
On vehicles with auxiliary heater, remove fuel lines
3
Chapter
“
Separating plug-in connectors
”
.
Unscrew union nut
1
using
union nut tool
3217
.
Pull fuel delivery unit and seal out of the opening in fuel tank.
Note
The lint-free cloth can be ordered from the
ServiceNet; Workshop Equipment; Techno equipment catalogue; BMK consumables
.
Always work carefully and ensure cleanliness when working on the fuel system. The fuel system reacts sensitively to the ingress of dirt.
If the fuel delivery unit needs to be exchanged, check the inside of the fuel tank for contaminants/soiling and, if necessary, clean with a lint-free cloth.
If fuel delivery unit is to be renewed, old delivery unit must be drained before disposal.
Installing
Install in reverse order. In the process, note the following:
When inserting fuel delivery unit, ensure that
fuel gauge sender
G
is not bent.
Renew seal.
Insert seal for fuel delivery unit dry into opening of fuel tank.
Moisten seal with fuel only when installing fuel delivery unit.
Do not interchange supply line and return line (return line blue or with blue marking, supply line black).
Ensure that line connections are tight.
After installing fuel delivery unit, check that the supply, return and breather lines are still clipped onto the fuel tank.
Push sealing flange downwards against spring force and bring sealing flange into installation position.
Marking on flange
1
must align with marking on fuel tank
arrow
.
Tighten union nut
1
.
After installing fuel delivery unit, check that supply and return lines are still clipped onto fuel tank.
Observe installation position of fuel supply line to supplementary heater
Auxiliary heater, supplementary heater
Rep. gr.
82
Fuel supply system
.
Specified torques
Chapter
“
Assembly overview - fuel tank
”