Removing and installing fuel delivery unit: four-wheel drive vehicles — VW
Removing and installing fuel delivery unit: four-wheel drive vehicles on VW: 10 steps, engines AZX. What to remove, in what order, and what to check after.
Workshop procedure for VW — the exact step sequence and torque figures, straight from real workshop data.
🧭 Before you start
Fits: VW Passat B5 (3B)
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- If delivery unit is to be renewed, drain old delivery unit before disposal.
🔧 Engine codes this applies to
📋 Procedure
- First check whether a coded radio is fitted. If so, obtain anti-theft coding.
- With ignition switched off, disconnect earth strap from battery.
- Remove rear seat bench.
- Remove cover in floor.
- ⚠ Fuel supply lines are under pressure! Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. — Pull 4-pin connector and supply and return pipes (arrows) off flange.
- Unscrew locking ring with fuel tank sender unit tool3087.
- Pull flange and seal out of opening in fuel tank.
- Unclip fuel gauge senderG from reservoir housing and remove.
- Turn fuel delivery unit approx. 15° anti-clockwise onto stop with fuel pump tool3307 and remove. [Note: If delivery unit is to be renewed, drain old delivery unit before disposal.]
- Installation of fuel delivery unit is carried out in reverse order. [Note: Do not bend fuel gauge sender when installing.Insert seal for flange or fuel delivery unit dry into opening of fuel tank.Moisten seal with fuel only when installing flange or fuel delivery unit.Do not interchange supply and return hoses (return hose -blue-).Ensure that fuel lines are tight.Secure fuel hoses with spring-type clips.Note Installation position of fuel delivery unit flange: Mark on flange (1) must align with mark on fuel tank (2).After installing fuel delivery unit flange, check that the supply, return and breather pipes are still clipped onto fuel tank.]
Other VW procedures
- Checking misfiring detection – VW Passat B5 2.3 AZX
- Checking injectors for leaks and quantity injected – VW
- Checking accelerator position sender – VW
- 5-cylinder injection engine (4-valve), mechanics — Valve gear · 2 torque figures
- Checking intake manifold change-over – VW Golf IV / Bora
- Removing engine · 41 torque figures
- Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
- Adjusting valve timing – VW Passat B5 · 83 torque figures
- Removing and installing camshafts – VW Passat B6 · 39 torque figures
- Removing and installing coolant pump · 53 torque figures
Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.