Volkswagen Workshop Service and Repair Manuals

Removing and installing fuel delivery unit, fuel gauge sender   Note After removing fuel delivery unit, check fuel tank for heavy soiling and clean if necessary. Special tools and workshop equipment required

t  Special wrench -T10202-

t  Torque wrench (40…200 Nm) -V.A.G 1332- Removing:   Caution Prerequisites: Fuel tank must not be more than 3/4 full. This ensures that the fill level is below the flange of the fuel delivery unit.   Note t  If necessary, drain fuel tank using fuel extractor -VAS 5190-. t  Note safety precautions before beginning work → Chapter. t  Observe rules for cleanliness → Chapter. t  Assembly overview - fuel tank → Chapter. –  Remove bench seat → General body repairs, interior; Rep. gr.72.

–  Remove cover -1- with fuel pump control unit -J538--2- from fuel delivery unit.   WARNING Fuel supply line is pressurised. Wear eye protection and protective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Pull off connector -arrow-.

–  Pull fuel lines -1- and -2- off flange. Detach push-on connectors → Chapter   Note On vehicles with auxiliary heater the connector and the fuel line of the metering pump -V54- must also be separated.

–  Open locking ring using wrench -T10202- and raise flange slightly. –  Pull fuel delivery unit and seal out of the opening in fuel tank.   Note t  If delivery unit is to be renewed, drain old delivery unit before disposal. t  Observe waste disposal regulations. Installing: –  Renew seal. –  Insert seal for fuel delivery unit dry into opening of fuel tank. –  Coat inner side of seal with fuel. –  When inserting fuel delivery unit, ensure that fuel gauge sender is not bent.

–  Press sealing flange down against spring pressure, and move sealing flange to installation position. l  Tab -2- on sealing flange must be between lugs -1- and -3- on fuel tank. l  The -arrow- points forwards. –  Tighten sealing flange. l  Specified torque: 110 Nm

–  Reconnect supply line-1- (black). –  Reconnect fuel return line -2- (blue or blue marking).

–  Reconnect connector -arrow-. –  Ensure push-fit couplings and electrical connectors are secured properly by pulling. Further installation is performed in the reverse sequence. In the process, note the following: t  Observe installation position of fuel feed line to auxiliary heater → Auxiliary heater; Rep. gr.82.

t  The -arrow- on the cover points forwards.