Fuel delivery unit, removing and installing: Removing

Observe safety precautions → Safety precautions when working on fuel supply system .

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 ³ /₄ . Drain fuel tank if necessary. Procedure → Fuel tank, draining .
Observe procedures for disconnecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

Fig 1: Pushing Cover Over Battery Toward Right And Removing It Upward

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

Fig 2: Locating Battery Ground Strap

Courtesy of VOLKSWAGEN UNITED STATES, INC.

With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Sedan:

Remove carpeting in luggage compartment.
Fold forward right rear seat backrest, if necessary.

Wagon:

Remove left 1/3 backrest →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.
Remove left side luggage compartment trim and dirt tray →
- 70 - INTERIOR TRIM
- 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
.

All models:

Fig 3: Unbolting Cover For Locking Flange In Luggage Compartment

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt cover for locking flange in luggage compartment - arrows -.

Fig 4: Disconnecting Electrical Harness Connector At Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - at locking flange.

Fig 5: Identifying Fuel Supply Line And Fuel Return Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

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

CAUTION: The fuel delivery unit may only be removed when fuel tank is maximum ³ /₄ filled. Otherwise, a large amount of fuel will spill out.

Fig 6: Removing/Installing Locking Ring With Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove locking ring with wrench T10202.
Lift fuel delivery unit slightly out of fuel tank opening and remove seal.

Fig 7: Removing/Installing Suction Jet Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

If fuel delivery unit is still inserted in fuel tank, slide locking flange slightly to side.
Reach through the gap between locking flange and installation opening in fuel tank and pull off suction jet line - 1 - from suction jet pump, by pressing release button.
Release suction jet pump - arrows - and remove it.
Remove fuel delivery unit.

NOTE:

When removing fuel delivery unit, be sure not to bend floater arm of fuel level sensor G.
Be aware that fuel is still in the fuel delivery unit.