Volkswagen Workshop Service and Repair Manuals

Removing and installing fuel delivery unit Special tools and workshop equipment required

t  Union nut tool -3217-

t  Torque wrench -V.A.G 1332- Removing –  Note safety precautions before beginning work → Chapter. –  First check whether a coded radio is fitted. If so, obtain anti-theft coding. –  With the ignition switched off, disconnect battery earth strap. –  Fold rear seat bench forwards. –  Remove cover from fuel delivery unit.   WARNING Fuel system is under pressure! Wear protective glasses and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. –  Pull 4-pin connector as well as supply and return pipes off flange.   Note To do this, press down buttons on hose couplings.

–  Unscrew union nut with union nut tool -3217-. Vehicles with four-wheel drive

–  Now disconnect 2-pin connector -1-, and fuel supply hose coupling -2- to suction jet pump.   Note To do this, press down buttons on hose couplings.

–  Lift fuel delivery unit slightly and pull bracket with return line -arrow- off upwards. Continuation for all vehicles –  Pull fuel delivery unit and seal out of opening in fuel tank.   Note If delivery unit is to be renewed, drain old delivery unit before disposal. Installing –  Installation of fuel delivery unit is carried out in reverse order.   Note t  Do not bend fuel sender when installing. t  Insert flange/fuel delivery unit seal dry into fuel tank opening. t  Moisten seal with fuel only when installing flange or fuel delivery unit. t  Ensure that fuel hoses are tight. t  After installing fuel delivery unit, check that supply, return and breather lines are still clipped onto fuel tank. Front-wheel drive vehicles

t  Note installation position of fuel delivery unit flange: mark on flange must align with mark on fuel tank -arrows-. Vehicles with four-wheel drive

t  Note installation position of fuel delivery unit flange: mark on flange must align with mark on fuel tank -arrows-.