Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ V.A.G 1331 Torque wrench (5 ... 50 Nm)

Removing

Prerequisites

• ● The fuel tank must be empty

Notes:

• ◆ Observe safety precautions before starting work .
• ◆ Fuel extraction unit VAS 5190 is recommended for emptying fuel tank. Contrary to the operating instructions the draining must not occur via the filler neck in this engine/vehicle, otherwise inner components will be damaged. Drain fuel tank only via the opened flange.

• ‒ First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
• ‒ With the ignition switched off disconnect the battery earth strap.
• ‒ Fold rear seat bench forwards.
• ‒ Remove cover from fuel delivery unit.

• ‒ → Pull 4-pin connector -1- off.
• ‒ Unscrew nuts -2- and take flange -3- off.

• ‒ → Disconnect connector-1-.
• ‒ Remove seal -2-.
• ‒ Drain fuel tank via flange opening, e.g. with VAS 5190.

→ Note:

For ease of illustration, the fuel tank upper shell is not shown. The components are shown simplified.

• ‒ Separate connector -1- on the wiring to the suction jet pump -2-. To do this press safety ring on connector in.

• ‒ → Turn fuel delivery unit -3- in anti-clockwise direction (approx. 45°), take it out of the bayonet joint and place to side.

Note:

Observe that the strainer filter and the fuel gauge sender are not damaged.

• ‒ Remove fuel return hose -6- first from the fuel filter and then the supply hose -5-.

• ‒ → At first take out the supply pipe -1- of the flange cut -out and then the return hose -2-, and after this carefully take out the fuel supply unit -3-.

Notes:

• ◆ When removing the fuel supply unit observe that the fuel gauge sender is not damaged.
• ◆ If the fuel delivery unit is to be renewed then drain old fuel delivery unit before disposal.

Installing

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

• ‒ → Connect connectors -1-, -3- and -4- (outer supply pipe -3-, return hose -4- centre of fuel retainer).

Note:

The supply and return hose connectors must audibly engage. Check for correct seat by tightening.

• ‒ Turn the fuel delivery unit -2- in the bayonet joint to right onto limit stop.

• ‒ → Fit new seal -2- with the bulge facing the fuel tank.
• ‒ Place the connector -1- in direction of arrow against the fuel gauge sender behind the fuel supply unit.

Note:

The working area of the float must not be reduced.

• ‒ → Fit locking device -3- so that the arrow -A- is parallel to the vehicle longitudinal axle and shows backwards -B-.
• ‒ Tighten nuts -2- in a diagonal sequence.

• Torque setting: 7 Nm

• ‒ Fit 4-pin connector -1-.
• ‒ Adapting (matching) engine control unit to throttle valve control part => page 24-43Adapting components and functions.
• ‒ If the fault memory has been erased or the engine control unit was disconnected from permanent positive, the readiness code must be generated again => page 24-43, Adapting components and functions.