Removing and installing fuel delivery unit (Golf Plus, Golf, Scirocco, Eos) — VW

🧭 Before you start

Check the tank is no more than 3/4 full, remove the bench seat and lift off the cover with J538. Release the pressurised supply and return lines under a cloth, open the locking ring with T10202 and lift out the delivery unit with its seal. Fit a new seal dry, coat its inner side with fuel, insert the unit without bending the gauge sender, press the flange down into position and tighten the ring. Reconnect supply (black), return (blue) and the connector, then pull-test every coupling.

Fits: VW Golf V / Jetta (1K, 2003–2009), VW Golf VI (5K, 2008–2013); platform codes 5M1, 1F7, 137, 521

• Renewed: seal

Don't miss

• Fuel level must be at most 3/4 so it sits below the flange opening.
• Fit a new seal dry into the tank, then wet its inner side with fuel.
• Do not bend the fuel gauge sender arm when lowering the unit in.
• Supply line is black, return is blue or blue-marked; do not cross them.
• On cars with an auxiliary heater, also separate the metering pump V54 line and connector.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ 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. — Remove bench seat General body repairs, interior72Removing and installing bench seat.
2. Remove cover (1) with fuel pump control unit J538(2) from fuel delivery unit.
3. ⚠ 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).
4. Pull fuel lines (1) and (2) off flange. [Note: Press in securing ring to release fuel lines.On vehicles with auxiliary heater the connector and the fuel line of the metering pump V54 must also be separated.]
5. Open locking ring using wrench T10202 and raise flange slightly.

6. Pull fuel delivery unit and seal out of the opening in fuel tank. [Note: If delivery unit is to be renewed, drain old delivery unit before disposal.Observe waste disposal regulations.]
7. Renew seal.
8. Insert seal for fuel delivery unit dry into opening of fuel tank.
9. Coat inner side of seal with fuel.
10. When inserting fuel delivery unit, ensure that fuel gauge sender is not bent.
11. Press sealing flange down against spring pressure, and move sealing flange to installation position.
12. Tighten sealing flange.
13. Reconnect supply line(1) (black).
14. Reconnect fuel return line (2) (blue or blue marking).
15. Reconnect connector (arrow).
16. Ensure push-fit couplings and electrical connectors are secured properly by pulling.

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