Fuel Delivery Unit

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. 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 safety precautions before beginning work. Refer to SAFETY PRECAUTIONS .

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

-- Switch off the ignition, switch off all electrical components and remove the ignition key.

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

-- Remove the cover -1- with the fuel pump control module -2-.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

The fuel supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting, wrap a cloth around the connection point. Then release the pressure by carefully disconnecting the connection.

-- Disconnect the 5 pin electrical connector -1-, black supply line -2- and blue return line -3-.

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 the securing ring to disengage the lines.

-- Remove the locking ring using the T10202.

Fig 3: Identifying Wrench T10202 In Locking Ring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lift the fuel delivery unit with sealing ring 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 of fuel before disposing of.

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 opening of fuel tank dry.
Only lubricate the seal with fuel on the inside when installing the fuel delivery unit.
When installing the fuel delivery unit into fuel tank, be sure not to bend the fuel level sensor arm.
Note the installed position of the fuel delivery unit: The tab -2- on the fuel delivery unit must lie between the tabs -1 and 3-. -Arrow- points in direction of vehicle 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 the black supply line and blue return line (see arrows on the fuel delivery unit).
Make sure the fuel lines are securely fastened.
After installing the fuel delivery unit, check whether the supply and return lines are still clipped in on the fuel tank.
If the fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump. Refer to vehicle diagnosis, testing and information system VAS 5051 or vehicle diagnosis and service system VAS 5052.