Removing and installing fuel delivery unit/fuel gauge, engine codes CBAA, CBAB, CBAC, CBBB — VW

🧭 Before you start

Fits: VW Passat CC (357, 2008–2012)

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• Always follow safety precautions .
• The fuel tank must not be more than 1/2 full when removing the suction-jet pump. Empty fuel tank if necessary .
• Press in securing ring to release fuel lines.
• Press in securing ring to release fuel line.
• If delivery unit is to be renewed, drain old delivery unit before disposal.

🔧 Engine codes this applies to

📋 Procedure

1. Always follow safety precautions .
2. First check whether a coded radio is fitted. If so, obtain anti-theft coding.
3. With the ignition switched off, disconnect battery earth strap.
4. The fuel tank must not be more than 1/2 full when removing the suction-jet pump. Empty fuel tank if necessary .
5. Remove rear bench seat General body repairs, interior72Rear seats; Removing and installing bench seat / individual seats.

6. Remove cover from fuel delivery unit.
7. Pull supply line (1), return line (2), and if fitted supply line (3) to metering pump V54 and 5-pin connector (5) off fuel delivery unit flange. [Note: Press in securing ring to release fuel lines.]
8. Open locking ring using wrench T10202.
9. Lift sender flange.
10. Pull fuel line (1) off suction-jet pump (if fitted). [Note: Press in securing ring to release fuel line.]
11. Press tab (2) of suction-jet pump in (direction of arrow) and unclip from fuel delivery unit
12. Pull fuel delivery unit along with suction-jet pump out of opening in fuel tank. [Note: If delivery unit is to be renewed, drain old delivery unit before disposal.]
13. Installing the fuel delivery unit is carried out in reverse order of removal. [Note: For fuel delivery units of the new generation the suction jet pump is no longer available. If the fuel delivery unit is to be renewed, remove suction jet pump.When inserting fuel delivery unit, ensure that fuel gauge sender is not bent.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.Fuel lines are to be installed free of kinks.Do not interchange supply line and return line (return line blue or with blue marking, supply line black).After installing fuel delivery unit, check that fuel lines are still clipped onto fuel tank.Observe installation position of fuel delivery unit .Connections for fuel lines must engage »audibly« when joined.Take note of colour assignment when installing the connections !Ensure push-on coupling is secured properly by pulling.Separate push-on couplings .]

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