CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
7
Repairing fuel supply (Passat, CC)
Note
♦ Fuel hoses on the engine must only be secured with spring-
type clips which conform to the production standard.
♦ Spring-type clip pliers - VAS 6499- or space saving hose clip
pliers - VAS 6362- are recommended for installation/removal
of spring-type clips.
Safety precautions when working on fuel supply system
⇒ page 278 .
Comply with rules for cleanliness ⇒ page 280 .
Removing and installing fuel gauge sender - G- ⇒ page 330 .
Check fuel pump ⇒ page 331 .
7.1
Removing and installing fuel delivery
unit
Special tools and workshop equipment required
♦ Special wrench - T10202-
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
326
Rep. gr.20 - Fuel supply system
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
Remove fuel delivery unit:
Caution
Condition:
3
•
The fuel tank must not be more than / full. This ensures
4
that the fill level is below the flange of the fuel delivery unit.
Procedure:
Note
♦ When replacing fuel delivery unit, check fuel tank for heavy
soiling and clean if necessary.
♦ Note safety precautions before beginning work ⇒ page 278 .
♦ Observe rules for cleanliness ⇒ page 280 .
♦ Assembly overview - fuel tank ⇒ page 281 .
– If necessary, empty fuel tank using fuel extractor - VAS 5190-
⇒ page 283 .
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Removing and installing bench seat .
– Remove cover -1- with fuel pump control unit - J538- -2- from
fuel delivery unit.
– First check that connector -A- is securely seated by pulling the
connector without pressing the catch. The connector can
cause a fault if it has not been fitted correctly.
– Now pull off connector.
– Check the contacts on the connector and on the fuel delivery
unit for damage.
WARNING
Fuel supply line is pressurised. Wear protective goggles and
protective clothing to avoid injury and contact with the skin.
Wrap a cloth around the connection before loosening hose
connections. Then release pressure by carefully pulling hose
off connection.
7. Repairing fuel supply (Passat, CC)
327
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Pull fuel line -B- off flange.
Note
♦ Press in securing ring to release fuel line.
♦ On vehicles with auxiliary heater, the connector and the fuel
line of the metering pump - V54- must also be disconnected.
– Open locking ring using key - T10202- .
Caution
Do not cant key - T10202- and press against locking ring firmly.
If the key slips off, the fuel delivery unit can be damaged.
– Lift flange.
– Separate coupling -A- and remove suction-jet pump -B-. Do
this by pressing lugs -arrows- together.
Note
Press in safety ring of coupling -A- to release fuel line.
– Pull seal and fuel delivery unit out of opening of fuel tank.
Note
♦ If delivery unit is to be renewed, drain old delivery unit before
disposal.
♦ Observe disposal regulations!
Install fuel delivery unit:
Caution
Do not bend float arm of fuel gauge sender - G- when installing.
– Insert fuel delivery unit (without suction-jet pump) into fuel
tank.
328
Rep. gr.20 - Fuel supply system
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– Install suction-jet pump -B- and reconnect coupling -A-. Check
coupling is secured properly by pulling.
– Push flange onto fuel delivery unit.
Note
Ensure hoses are secured correctly.
– Now pull seal -A- over the flange and seat it in the opening of
the fuel tank.
– Moisten seal lightly with fuel and push flange into fuel tank.
– Observe installation position: Marking -A- points towards rear
of vehicle.
– Tighten locking ring using wrench - T10202- . Specified torque
⇒ Item 16 (page 282) .
The remaining installation steps are carried out in the reverse se‐
quence of removal. During this procedure, observe the following:
7. Repairing fuel supply (Passat, CC)
329
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
♦ The -arrow- on the cover points forwards.
♦ Fuel lines are to be installed free of kinks.
♦ Ensure wiring/line connections are secured properly by pulling
back.
7.2
Removing and installing fuel gauge
sender - G-
Note
♦ Note safety precautions before beginning work ⇒ page 278 .
♦ Observe rules for cleanliness ⇒ page 280 .
♦ Assembly overview - fuel tank ⇒ page 281 .
Removing fuel gauge sender
– Remove fuel delivery unit ⇒ page 326 .
– Pull fuel gauge sender - G- slightly to side and upwards at the
same time.
– If the sender cannot be released in this way, the retaining tabs
-arrows- must also be pushed to the side slightly.
– Note colour co-ordination of cables for reinstallation.
330
Rep. gr.20 - Fuel supply system
2024 VW Passat Owner's Manual
VW Passat B7 Service & Repair Manual
VW Passat B6 Service & Repair Manual
