Fuel Delivery Unit

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

Requirement:

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

Removing

NOTE:

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

Drain the fuel tank using the fuel extracting device -VAS 5190- if necessary.

Read the safety precautions before beginning work. Refer to SAFETY PRECAUTIONS .

Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Fuel tank and attachments overview. Refer to FUEL TANK AND ATTACHMENTS OVERVIEW .

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

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

Fig 1: Identifying Cover With Fuel Pump Control Module J538

Courtesy of VOLKSWAGEN UNITED STATES, 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: Identifying Fuel Pump Control Module Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Disconnect the connector.

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

WARNING:

The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

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

Fig 3: Identifying Fuel Lines At Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Press in the securing rings to disengage the fuel lines.

-- Remove the lock ring using the wrench -T10202- and raise the flange slightly.

Fig 4: Identifying Locking Ring And Wrench T10202

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

NOTE:

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

Follow disposal regulations.

Installing

-- Replace the seal.

-- Install the new fuel delivery unit seal into the fuel tank opening dry.

-- Lubricate the inner side of the seal with fuel.

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

-- Press the lock ring down and bring it into its installed position.

Fig 5: Identifying Fuel Delivery Unit, Installed Position

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The tab -2- on the lock ring must lie between the tabs -1 and 3- on the fuel tank.
The -arrow- points in the direction of travel.

-- Tighten the lock ring.

Tightening specification: 110 Nm

-- Connect the supply line -1- (black).

Fig 6: Identifying Fuel Lines At Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Connect the return line -2-. It is blue or has a blue mark.

-- Connect the connector -arrow-.

Fig 7: Identifying Fuel Pump Control Module Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Pull on the lines and connector to make sure they are securely fastened.

The rest of the installation is performed in the reverse order of removal. When doing this note the following:

The -arrow- on the cover points in the direction of travel.

Fig 8: Identifying Mark To Indicate Direction Of Travel
Courtesy of VOLKSWAGEN UNITED STATES, INC.