Removing and installing fuel delivery unit in fuel tank — VW

🧭 Before you start

Fits: VW Passat B5 (3B)

Don't miss

• If delivery unit is to be renewed, drain old delivery unit before disposal.

🔧 Engine codes this applies to

📐 6 workshop diagrams for BDN

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Note safety precautions before beginning work .
2. Switch off ignition and all electrical consumers and remove key.
3. With the ignition switched off, disconnect battery earth strap.
4. Fold the rear seat bench down.
5. Remove cover from fuel delivery unit.

6. Pull 4-pin connector and supply and return lines off flange (arrows).
7. ⚠ Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid eye injuries and skin contact. Place a cloth over connection before loosening hose clip. Then release pressure by carefully pulling hose off connection. — Seal lines so that fuel system is not contaminated by dirt.
8. Remove locking ring with spanner3087.
9. Pull flange and seal out of opening in fuel tank.
10. Unclip fuel gauge senderG from reservoir housing and remove.
11. Turn fuel delivery unit approx. 15° anti-clockwise onto stop with spanner3087 and remove. [Note: If delivery unit is to be renewed, drain old delivery unit before disposal.]
12. 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.Ensure that fuel hoses are tight.Do not interchange supply and return lines.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

• Removing, installing and checking suction jet pumps – VW BDN
• Renewing engine control unit – VW Passat B5
• Installing upper sump – VW Passat B5 4.0 BDN/BDP · 1 torque figures
• Repairing valve gear (cylinder banks 1 and 2) – VW 4.0 BDN/BDP
• Checking oil pressure and oil pressure switches – VW 4.0 BDN
• 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