Fuel Delivery Unit: Removing

-- Fuel tank may be a maximum of ³ /₄ full. This ensures the fuel level is below the fuel delivery unit flange.

-- Turn off the ignition and all electric consumers.

-- Remove the ignition key.

-- Remove the bench seat. Refer to REMOVAL AND INSTALLATION .

-- If equipped, remove the Fuel Pump Control Module -J538- -2- from the cover -1-.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip the cover -1- at the tabs -arrows- using the Trim Removal Wedge 3409.

Fig 2: Identifying Right Cover

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-- Release and disconnect the connector -arrow-.

Fig 3: Fuel Pump Control Module Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -arrow-.

-- Check the contacts on the connector and on the fuel delivery unit for damage.

-- Disconnect the fuel line -1 and 2- from the flange on the fuel delivery unit. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 4: Fuel Lines At Flange

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Collect leaking fuel with a cloth.

-- Open the locking ring using Wrench - Fuel Sending Unit T10202 and lift the flange slightly.

Fig 5: Identifying Locking Ring And Wrench T10202

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-- Pull the sealing flange -2- out of the opening in the fuel tank just a little.

Fig 6: Identifying Locking Flange And Seal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove seal -1- on the opening in the fuel tank.

-- Carefully pull the locking flange with the fuel line -2- as far as possible out of the fuel tank opening.

-- Turn and tilt it as needed.

-- Be careful not to bend the swimmer arm on the fuel level sensor when removing the fuel delivery unit.

-- Place a cloth to catch the leaking fuel, because the fuel delivery unit is still filled.