Fuel Delivery Unit

WARNING: This page is about a different car, the 2010 Volkswagen Jetta and 2009 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Wrench T10202
Torque Wrench (40-200 Nm) V.A.G 1332

CAUTION:

Observe the safety precautions when working on the fuel supply system. Refer to SAFETY PRECAUTIONS .
Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Always follow these instructions before and during work.

Conditions

The fuel tank may be a maximum of 1/2 full.

NOTE:

Drain the fuel tank if necessary using the fuel extracting device VAS 5190. Refer to FUEL TANK, DRAINING .

Removing

CAUTION:

Electronic components could be destroyed when the battery is disconnected:

Follow the required steps when disconnecting the battery.

-- Turn off the ignition and disconnect the ground cable -arrow- from the battery. Refer to Removal and Installation .

Fig 1: Identifying Battery And Ground Cable

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the rear seat bench. Refer to Removal and Installation .

-- Remove the cover -1- for the fuel delivery unit. the arrow -2- points in direction of travel.

Fig 2: Identifying Fuel Delivery Unit Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

The fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin.
Before loosening the connection, place a cloth around the connection point. Then release pressure by carefully disconnecting the line.

-- Disconnect the connector -1-, the black supply line -2- and the blue return line -3-.

Fig 3: Identifying 4-Pin Connector, Black Supply Line And Blue Return Line From Fuel Delivery Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Press in the securing ring to disengage the fuel lines.

-- Seal the lines so that the fuel system is not contaminated by dirt, etc.

-- Remove the lock ring using wrench T10202.

Fig 4: Identifying Wrench T10202 In Locking Ring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the fuel delivery unit and the seal from the fuel tank opening.

NOTE:

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

Follow disposal regulations.

Installing

Install in reverse order of removal. When doing this note the following:

Lock ring tightening specification: 110 Nm.
Do not bend the fuel level sensor -G- arm when inserting the fuel delivery unit.
Replace the fuel delivery unit seal if damaged and install it in the fuel tank opening dry.
Lubricate the seal with fuel only when installing the fuel delivery unit.
Pay attention to the installed position of the fuel delivery unit flange. Refer to Figure.
Route the fuel lines free of kinks.
Do not interchange the supply and return lines (the return line is blue, the supply line is black).
Make sure the line connections are securely fastened.

-- Observe the notes after connecting the battery. Refer to Removal and Installation .