Suction jet pumps (vehicles with engine code BJS), removing and installing

WARNING: This page is about a different variant/trim than selected.

Function

In vehicles with All Wheel Drive (AWD), due to the construction of the fuel tank, it is required to pump fuel from the area of the Fuel Level Sensor 2 (Refer to Fuel tank with attachments and fuel filter (vehicles with engine code BJS), removing and installing , item 17) to the fuel delivery unit (Refer to Fuel tank with attachments and fuel filter (vehicles with engine code BJS), removing and installing , item 30) via a suction jet pump.

The suction jet pump is driven via an additional connection by the fuel pump via the fuel supply line.

NOTE: A test must only be performed, if the engine stops running due to lack of gasoline, even though the fuel gauge indicates the fuel tank is still filled via a reserve.

Recommended special tools and equipment

Fig 1: 3217 Ring Nut Spanner

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3217 ring nut wrench

Fig 2: Torque Wrench V.A.G. 1332 (40 To 200 Nm)

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V.A.G 1332 torque wrench (40 to 200 Nm)

Requirements

Parking brake must be engaged or else daylight driving lights will be switched on.
Ignition switched off.
Fuel tank must be empty. Refer to Fuel tank, draining , emptying fuel tank.

Removing

Observe safety precautions. Refer to Safety precautions when working on fuel supply system .

Observe rules for cleanliness. Refer to Rules of cleanliness .

First determine whether a coded radio is installed. In this case, determine the anti-theft coding.
Switch ignition off and disconnect Battery Ground (GND) strap.
Fold rear seatback forward.
Remove both covers.

Remove flange of Fuel Pump (FP) unit (right side of vehicle). Refer to Fuel Pump (FP) unit, removing and installing , removing and installing Fuel Pump (FP) unit.

Fig 3: Removing/Installing Fuel Level Sensor 2 G169 Union Nut On Left Side Of Vehicle

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Unscrew union nut for Fuel Level Sensor 2 -G169- on left side of vehicle using wrench 3217.
Lift fuel level sensor 2 upward as far as possible.

Fig 4: Separating Cable Ties From Fuel Lines & Spreading Apart The Mount For Suction Jet Pump On Fuel Level Sensor 2

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Cut cable tie on supply line -arrow- and carefully expand bearing for suction jet pump on fuel level sensor 2 -guiding arrows-.
Now the suction jet pump with supply- and return line can be unclipped and removed at fuel level sensor 2.

Installing

Ensure fuel lines at suction jet pump are connected securely and in proper condition.
Also check suction jet pump for possible dirt.

If no malfunction can be detected:

Re-install suction jet pump and fuel level sensor 2 in reverse order of removal.

NOTE:

Always replace seals if they are swelled up due to fuel.
Insert dry flange seal into opening of fuel tank.
Coat seal with fuel when installing.
While inserting, make sure fuel level sensor 2 is not bent.
Note installation position of fuel level sensor 2:Marking on sensor must align with marking on fuel tank.

Erase DTC memory of Engine Control Module (ECM). Refer to Diagnostic mode 4: Reset/erase diagnostic data
Generate readiness code. Refer to Readiness code, generating