Fuel Delivery Unit: Removing

WARNING: This page is about a different variant/trim than selected.

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 as necessary using the fuel extracting device VAS 5190. Refer to FUEL TANK, DRAINING .

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

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

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

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

Fig 1: Identifying Cover With Fuel Pump Control Module J538

Courtesy of VOLKSWAGEN UNITED STATES, INC.

WARNING:

Fuel system is under pressure!

Always wear protective eye-wear 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 connector -arrow-.

Fig 2: Fuel Pump Control Module Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 3: Fuel Lines At Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Press the locking ring to release the fuel lines.

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

Fig 4: Removing Locking Ring Using 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.