Right fuel delivery unit with Fuel Pump (FP) G23 , removing and installing: Removing

Observe safety precautions → Safety precautions .

Observe rules for cleanliness → Rules for cleanliness .

CAUTION:

To remove the fuel delivery unit, the fuel tank may only be filled to a maximum of ¹ /₃ . Empty fuel tank if necessary. Procedure → Fuel tank, emptying .

CAUTION: Observe safety precautions when disconnecting the battery → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Fig 1: Removing Cover Of Right Luggage Compartment Side Trim

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Remove cover of right luggage compartment side trim - arrows -.

Fig 2: Removing Cover Above Battery

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Remove cover - 1 - above battery.

NOTE:

Ignore - 2 -.

Fig 3: Disconnecting Battery Ground (GND) Strap

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
Remove trim for luggage compartment floor.

NOTE:

To remove and install fuel delivery unit, remove vehicle tool kit and spare wheel from luggage compartment. It is then possible to sit or kneel in spare wheel well.

Fig 4: Removing/Installing Cover For Right Locking Flange

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Remove cover for right locking flange - arrows -.

Fig 5: Disconnecting/Connecting Electrical Connectors At Right Locking Flange

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Disconnect electrical connectors - 1 - and - 2 - at right locking flange.

Fig 6: Identifying Fuel Return Line & Fuel Supply Line

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Mark fuel return line - 1 - and fuel supply line - 2 -.

CAUTION: Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.

Pull both lines from locking flange, by pressing release buttons.

Fig 7: Removing/Installing Locking Ring Using Wrench T10202

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Remove locking ring using wrench T10202.

Fig 8: Disconnecting/Connecting Electrical Connectors On Underside Of Right Locking Flange

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Pull off locking flange and remove seal.
Disconnect electrical connectors - 1 to 3 - on underside of right locking flange.

Fig 9: Identifying Fuel Lines & Right Fuel Delivery Unit With Fuel Pump (FP) G23

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NOTE:

To separate the line couplings that are mentioned later in the description, pull fuel lines out of the fuel tank opening.
To improve clarity, the following illustration shows several components not installed.

Through right fuel tank opening, separate fuel lines - 1 - and - 2 - for left fuel delivery unit by pressing release buttons.

3 - Right fuel delivery unit with Fuel Pump (FP) G23

Fig 10: Unclipping Filling Line From Front Of Right Fuel Delivery Unit

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Unclip filling line from front of right fuel delivery unit - arrow -.

Fig 11: Removing/Installing Cover For Left Locking Flange

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Remove cover for left locking flange - arrows -.

Fig 12: Disconnecting/Connecting Electrical Connectors At Left Locking Flange

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Disconnect electrical connectors - 1 - and - 2 - at left locking flange.

Fig 13: Removing/Installing Locking Ring Using Wrench T10202

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Remove locking ring using wrench T10202.

Fig 14: Disconnecting/Connecting Electrical Connectors On Underside Of Left Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull off locking flange and remove seal.
Disconnect electrical connectors - 1 to 3 - on underside of left locking flange.

Fig 15: Identifying Suction Jet Pipes

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Through left fuel tank opening, separate suction jet pipe - 3 - from Y-piece, by pressing release button.
Pull suction jet pipe out toward right fuel tank opening.

Fig 16: Inserting Fuel Delivery Line And Fuel Level Sensor 4 G393 Until It Engages Audibly On Right Fuel Delivery Unit

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Through right fuel tank opening, press release buttons - arrows - and remove fuel delivery line - 2 - and Fuel Level Sensor 4 G393 - 1 -.
Swing Fuel Level Sensor 4 G393 aside to right.

Fig 17: Pressing Down Both Retaining Clasps On Fuel Delivery Unit Support

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Press down both retaining clasps on fuel delivery unit support - arrows -.
Remove fuel delivery unit.

NOTE:

Be aware that fuel is still in the fuel delivery unit.