Fuel Delivery Unit

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Torque Wrench (40-200 Nm) (V.A.G 1332)


• Observe the safety precautions when working on the fuel supply system. Refer to => [ Safety Precautions ] Fuel Supply.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

Always follow these instructions before and during work.

Conditions

• The fuel tank may be a maximum of 1/2 full.

• Drain the fuel tank if necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Procedures.

Removing


Electronic components could be destroyed when the battery is disconnected:

• Follow the required steps when disconnecting the battery.

- Turn off the ignition and disconnect the ground cable - arrow - from the battery.






- Remove the rear seat bench.

- Remove the cover - 1 - for the fuel delivery unit. the arrow - 2 - points in direction of travel.







• The fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before loosening the connection, place a cloth around the connection point. Then release pressure by carefully disconnecting the line.

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






• Press in the securing ring to disengage the fuel lines.

- Seal the lines so that the fuel system is not contaminated by dirt, etc.

- Remove the lock ring using wrench (T10202).






- Remove the fuel delivery unit and the seal from the fuel tank opening.

• If the fuel delivery unit is to be replaced then drain the old delivery unit before disposal.

• Follow disposal regulations.

Installing

Install in reverse order of removal. When doing this note the following:

• Lock ring tightening specification: 110 Nm.

• Do not bend the fuel level sensor (G) arm when inserting the fuel delivery unit.

• Replace the fuel delivery unit seal if damaged and install it in the fuel tank opening dry.

• Lubricate the seal with fuel only when installing the fuel delivery unit.

• Pay attention to the installed position of the fuel delivery unit flange. For the Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, refer to => [ Installed Position, Fuel Delivery Unit Flange ] Fuel Tank Overview and for Jetta from MY 11, refer to => [ Installed Position, Fuel Delivery Unit Flange ] Fuel Tank Overview.

• Route the fuel lines free of kinks.

• Do not interchange the supply and return lines (the return line is blue, the supply line is black).

• Make sure the line connections are securely fastened.

- Observe the notes after connecting the battery.