Fuel Delivery Unit

WARNING: This page is about a different car, the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. 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

Removing

CAUTION:

Requirement:

The fuel tank may be a maximum of 3/4 full. This ensures the fuel level is below the fuel delivery unit flange.

NOTE:

When replacing the fuel delivery unit, check the fuel tank for visible contamination and clean if necessary.

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

Fuel Tank Assembly Overview. Refer to FUEL TANK AND ATTACHMENTS OVERVIEW .

-- Read the safety precautions before starting. Refer to SAFETY PRECAUTIONS .

-- Pay attention to the rules of cleanliness. Refer to CLEAN WORKING CONDITIONS .

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

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

-- Remove the cover -1- and the fuel pump control module -J538- -2-.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- First, pull on the connector -arrow- without pressing the retainer to make sure it is connected securely. If the connector was not connected correctly, it could cause a fault.

Fig 2: Fuel Pump Control Module Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -arrow-.

-- Check the contacts on the connector and the fuel delivery unit for damage.

WARNING:

The fuel system is under pressure!

Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

-- Disconnect the fuel lines -1 and 2- from the flange.

Fig 3: Fuel Lines At Flange

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Press in the securing ring to disengage the lines.

-- Remove the lock ring using the wrench T10202.

Fig 4: Identifying Locking Ring And Wrench T10202

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

NOTE:

When removing the fuel delivery unit, be sure not to bend the fuel level sensor arm.

When replacing the fuel delivery unit, empty the 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 the new seal for the fuel delivery unit into the fuel tank opening dry.
Only lubricate the seal with fuel on the inside when installing the fuel delivery unit.
When inserting the fuel delivery unit into the fuel tank, be sure not to bend the fuel level sensor arm.
Press the flange down and bring it into the installed position.
Note the installed position of the fuel delivery unit: The tab -2- on the fuel delivery unit must lie between tabs -1 and 3-. The -arrow- points in the direction of travel.

Fig 5: Fuel Delivery Unit, Installed Position
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Tighten the lock ring to 110 Nm.
Do not interchange the black supply line and blue return line (arrows on the fuel delivery unit flange).
Make sure the connectors and the fuel line are secure. Pull on them if necessary.
After installing the fuel delivery unit, check whether the supply and return lines are still clipped onto the fuel tank.