Fuel Delivery Unit

Special tools and workshop equipment required

Wrench for tank sensor T10202
Torque wrench V.A.G 1332

Removing

Fuel tank may be a maximum of ³ /₄ full.

NOTE:

Empty the fuel tank if necessary using the fuel extracting device VAS 5190 FUEL TANK DRAINING .

Read safety precautions before beginning work FUEL SUPPLY SYSTEM SAFETY PRECAUTIONS .

Observe the rules for cleanliness CLEAN WORKING CONDITIONS .

-- Turn the ignition and all electrical consumers off and remove the ignition key.

-- Remove seat bench Removal and Installation .

-- Unclip cover -1- from fuel delivery unit. Arrow -2- points in direction of travel.

Fig 1: Identifying Fuel Delivery Unit Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

The fuel or fuel lines in fuel system can become very hot (danger of scalding)!
In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!
Wear protective goggles and protective gloves when working on the fuel system!

-- Disconnect the connector -1-, the black supply line -2- and the blue return line -3- from the fuel delivery unit.

Fig 2: 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 securing ring to disengage the lines.

On vehicles equipped with an auxiliary heater, the metering pump -V54- electrical connector must also be disconnected and the fuel pipe must be removed.

-- Open locking ring using wrench T10202.

Fig 3: Identifying Wrench T10202 In Locking Ring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull fuel delivery unit with seal out of the opening in the fuel tank.

NOTE:

When removing fuel delivery unit, be sure not to bend sender for fuel gauge.

When replacing fuel delivery unit, empty old fuel delivery unit before disposing.

Installing

Installation of the fuel delivery unit is the reverse order of removal. When doing this note the following:

Insert dry new sealing ring of fuel delivery unit into opening of fuel tank.
Only coat seal with fuel on the inside when installing fuel delivery unit.
When inserting fuel delivery unit into fuel tank, be sure not to bend sender for fuel gauge.
Note installation position of fuel delivery unit: Tab -2- on fuel delivery unit must lie between tabs -1- and -3-. -Arrow- points in direction of travel.

Fig 4: Identifying Installation Position Of Fuel Delivery Unit
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Tighten the locking ring to 110 Nm.
Do not interchange black supply line and blue return line (arrows on flange of fuel delivery unit).
Make sure fuel lines are securely fastened.
After installing fuel delivery unit, check whether supply and return lines are still clipped in at fuel tank.