Fuel Delivery Unit

WARNING: This page is about a different car, the 2008 Volkswagen R32. 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) VAG 1332

Removing

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

NOTE:

Empty the fuel tank if necessary using the VAS 5190. Refer to FUEL TANK, DRAINING .

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

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

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

-- Remove the cover -arrows- from the fuel delivery unit.

Fig 1: Identifying Cover From Fuel Delivery Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Fuel system is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then release the pressure by carefully disconnecting the connection.

-- Disconnect the connector -1- and fuel lines -2 and 3- from the fuel delivery unit.

Fig 2: Identifying 5-Pin Connector, Black Supply Line And Blue Return Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Press in the securing ring to disengage the fuel lines.

-- Remove the locking ring using the T10202.

Fig 3: Identifying Wrench T10202 In Locking Ring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the fuel delivery unit out from the opening in the fuel tank and lay aside with lines the still attached.

-- Through the fuel tank opening, separate the suction jet pump pipe -2- from the suction jet pump, by pressing the release button.

Fig 4: Identifying Suction Jet Pipe & Fuel Delivery Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the fuel delivery line -1- by the pressing the release -arrow-.

-- Remove the fuel delivery unit.

NOTE:

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

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

Installing

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

When inserting fuel delivery unit into fuel tank, be sure not to bend the fuel level sensor arm.
Install a new dry seal for the fuel delivery unit into the opening in the fuel tank.
Only lubricate the seal with fuel when installing the fuel delivery unit.
Note the installed position of the fuel delivery unit. Refer to Figure.
Do not interchange the supply and return lines (return line is blue or has a blue marking, supply line is black).
Make sure the lines connections are securely fastened.