Fuel delivery unit, removing and installing

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Special tools, testers and auxiliary items required

Fig 1: 3217 Ring Nut Spanner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ring nut wrench 3217

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Torque wrench V.A.G 1332

Removing

Read safety precautions before beginning work refer to Safety precautions when working on fuel supply system .
First, check whether a coded radio is installed. If necessary, obtain the anti-theft coding.
With ignition switched off disconnect battery ground (GND) strap.
Remove cover under bench seat.

Pull off 4-pin connector such as supply and return lines from flange.

NOTE:

Press buttons together on hose connections to do this.

CAUTION: Fuel supply lines are under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

Fig 3: Removing/Installing Union Nut With Wrench 3217

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Use ring nut spanner 3217 to remove union nut.
Pull fuel delivery unit and seal out of opening in fuel tank.

NOTE:

If the delivery unit is to be replaced then drain old delivery unit before disposal.

Installing

Installation of fuel delivery unit is in reverse order of removal.

NOTE:

When inserting fuel delivery unit, be sure not to bend fuel gauge sensor.
Insert dry flange seal of fuel pump into opening of fuel tank.
Only coat seal with fuel when installing fuel delivery unit.
Ensure fuel hoses are seated securely.

Fig 4: Installed Position Of Flange Of Fuel Delivery Unit

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Note installation position of fuel delivery unit flange: Marking on flange must align with marking on fuel tank - arrows -.
After installing fuel delivery unit, check that the supply, return and breather lines are still clipped onto the fuel tank.

Perform "Procedure after interrupting voltage supply", refer to PROCEDURE AFTER VOLTAGE SUPPLY OPEN CIRCUIT .