Fuel delivery unit, removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2002 Volkswagen Jetta, 2002 Volkswagen GTI, 2001 Volkswagen Jetta, 2001 Volkswagen GTI, and 2000 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Review safety measures before starting work, refer to Safety precautions when working on the fuel supply system .

NOTE:

The battery ground strap must eventually be disconnected in the further course of work. Check whether the vehicle has a coded radio system. It may be necessary to disable the theft-deterrent feature by entering the appropriate code.

Disconnect battery ground strap with ignition off.
Fold rear seat forward.
Remove cover under seat.

Fig 1: Fuel Delivery Unit Connector & Supply And Return Lines

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove 4-way connector and feed and return lines from flange - arrows -.

NOTE:

Press the tabs on the hose couplings together for this.

CAUTION: The feed line is under pressure! Place clean rags around the hose connections, then reduce the pressure by disconnecting the hose very slowly and carefully.

Plug lines to prevent contamination of fuel system.

Fig 2: Removing/Installing Union Nut With Wrench 3217

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove union nut with union nut tool 3217.
Remove fuel delivery unit and sealing ring through fuel tank opening.

NOTE:

If the delivery unit is to be replaced, empty the old delivery unit before disposal.