Page 33 of 49
20-37
Test sequence
- Open fuse box cover on left side of instrument
panel.
- Remove fuse 28 from fuse holder (left row, 5Th
fuse from top).
- Connect remote control to right side of fuse 28 holder using adaptor
cable -arrow-.
- Connect tester lead to Battery +.
- Remove fuel filler cap.
- Remove engine cover.
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Page 34 of 49
20-38
Vehicles with 1.8 ltr. turbo engine
WARNING!
Fuel system is under pressure! Before
opening, place clean cloths around the
connections to be opened. Carefully loosen
the connections to relieve pressure.
Vehicles with 2.8 ltr. engine
WARNING!
Fuel system is under pressure! Before opening, place clean cloths
around the connections to be opened. Carefully loosen the
connections to relieve pressure. - Disconnect fuel return hose from connection on fuel distributor line.
- Connect auxiliary hose -arrow- to distributor line and hold in measuring
container.
- Disconnect fuel return hose from hose connection on fuel distributor
line.
- Connect auxiliary hose -arrow- to distributor line and hold in measuring
container.
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ge 34 of 49 Fuel su
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ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
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Page 35 of 49
20-39
All vehicles
- Operate remote control for 15 seconds.
Press remote button continuously
*) Minimum supply quantity cm
3/15 s
**)
Voltage on fuel pump with engine off and pump running (approx. 2
Volts less than Battery Voltage). - Compare fuel quantity pumped to specified value.
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ge 35 of 49 Fuel su
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ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
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Page 36 of 49
20-40
Fuel supply unit, removing and
installing
Vehicles with front wheel drive and 1.8 ltr.
turbo or 2.8 ltr. engine
Observe Safety measures Page 20
-1 .
Observe Rules of cleanliness Page 20
-4 .
Required special tools, testing equipment
and auxiliary equipment
3217 Union nut wrench
3307 fuel pump wrench
VAG1275 Hose clamp pliers
Removing
CAUTION!
Obtain the radio Anti-theft code from the
customer before disconnecting the Battery
Ground strap.
- Disconnect Battery Ground strap with ignition switched OFF.
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ge 36 of 49 Fuel su
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g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
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Page 37 of 49
20-41
- Open fuel-filler cap briefly and close again.
- If necessary, drain fuel tank using fuel cart
Page 20
-18
.
Note:
The fuel tank must not be filled more than
1/3
maximum.
- Remove connector flange cover under luggage
compartment trim.
WARNING!
Fuel system is under pressure! Before
opening, place clean cloths around the
connections to be opened. Carefully loosen
the connections to relieve pressure.
- Mark return line -2- and supply line -3- and pull off of cover flange.
- Unlatch and disconnect 4-pin harness connector -1-.
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ge 37 of 49 Fuel su
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ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
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Page 38 of 49
20-42
- Unscrew union nut with 3217 wrench.
- Remove cover flange and sealing ring from fuel tank opening.
- Disconnect sender for fuel gauge -G harness connector on inside of
cover flange.
- Disconnect return line on inside of cover flange by pressing unlatch
buttons.
Note:
If the supply unit is replaced, empty the old supply unit of any remaining
fuel before properly disposing of it. - Insert 3307 fuel pump wrench through fuel tank opening and place on
inner section of surge housing.
-
Using wrench 3307, turn surge housing inner section approx. 15 to
the left up to the stop and take fuel pump out complete with inner
section of housing.
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ge 38 of 49 Fuel su
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ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
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Page 39 of 49
20-43
Cover flange and surge housing inner
section, pre-assembling
If cover flange and supply unit were separated
- Pre-assemble parts Page 20
-27
.
Note:
Install a toothed washer beneath each of the nuts.
Angle position cover flange to inner section of surge housing 10
- Press together clamps for supply line (between pump and cover flange)
using VAG1275 pliers.
- Attach wiring to fuel pump
M4: 1.5 Nm M5: 2 Nm
- Attach wiring using fuel-resistant cable ties.
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ge 39 of 49 Fuel su
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ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
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Page 40 of 49
20-44
Installing
Installation is performed in the reverse order of
the removal procedure, during installation note
the following:
CAUTION!
Always refer to the latest parts catalog to
ensure that you use original equipment fuel
hose clamps.
- Install surge housing inner section, supply hose
and cover flange in fuel tank.
Note:
For clarity, the inner and outer surge housing sections are shown without
the tank. - Place inner section of surge housing into outer section of surge
housing (in tank) in such a way that notch 1 on inner section of surge
housing matches mark 2 on outer section of surge housing.
The inner section of the surge housing can be pressed downward
until it is clearly heard to engage.
- Put fuel pump wrench 3307 in place and turn surge housing inner
section with pump to the right approx. 15 to the stop. The notch -1-
will then be in front of the marking -3- (bayonet closure).
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ge 40 of 49 Fuel su
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ly system, servicin
g (vehicles with front wheel drive and 1.8 ltr. turbo or 2.8 ltr. en
gine
)
11/19/2002 htt
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