Fuel delivery unit, removing and installing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Fuel Siphoning Unit VAS 5190

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fuel siphoning unit VAS 5190

Fig 2: 3217 Ring Nut Spanner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ring nut wrench 3217
Torque wrench V.A.G 1332

Removing

NOTE:

Empty fuel tank using fuel siphoning unit VAS 5190.

Observe safety precautions before performing repair work, refer to Safety precautions when working on fuel supply system .

NOTE:

To perform work sequence, the Ground (GND) cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti-theft coding beforehand.

With the ignition switched off disconnect battery ground strap.
Remove right cover under the bench seat.

CAUTION: Fuel system is under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

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

NOTE:

Press buttons on hose couplings to do this.

Fig 3: Removing/Installing Union Nut With Wrench 3217

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Use ring nut spanner 3217 to remove union nut.

Fig 4: Identifying 2-Pin Connection, Such As Supply Line Hose Connection To Suction Jet Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect 2-pin connection - 1 -, such as supply line hose connection - 2 - to suction jet pump.

Fig 5: Lifting The Fuel Delivery Unit Slightly And Pulling Bracket With Return Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lift the fuel delivery unit slightly and pull the bracket with return line - arrow - off upward.
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 the fuel delivery unit is performed in the reverse order.

NOTE:

If seals are swollen with fuel, always replace.
Do not bend lever arm of fuel sender when installing.
Insert seal for fuel delivery unit and fuel level sensor 2 dry into opening of fuel tank.
Ensure fuel hoses are seated securely.

After installing fuel delivery unit, check that the supply, return and breather lines are still clipped onto the fuel tank.

Fig 6: 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 - arrow -.