Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSVOLKSWAGEN2004R32REPAIR AND DIAGNOSISENGINE PERFORMANCETUNE-UP3.2L VR6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BJS20 - FUEL SUPPLYFUEL SUPPLY SYSTEM COMPONENTS, REMOVING AND INSTALLINGFUEL DELIVERY UNIT, REMOVING AND INSTALLING

2004 Volkswagen R32

Fuel delivery unit, removing and installing

2004 Volkswagen R32SECTION Fuel delivery unit, removing and installing

Special tools, testers and auxiliary items required

Fig 1: Fuel Siphoning Unit VAS 5190

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fuel siphoning unit VAS 5190

Fig 2: 3217 Ring Nut Spanner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ring nut wrench 3217
Torque wrench V.A.G 1332

Removing

NOTE:

Empty fuel tank using fuel siphoning unit VAS 5190.

Observe safety precautions before performing repair work, refer to Safety precautions when working on fuel supply system .

NOTE:

To perform work sequence, the Ground (GND) cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti-theft coding beforehand.

With the ignition switched off disconnect battery ground strap.
Remove right cover under the bench seat.

CAUTION: Fuel system is under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

Pull off 4-pin connector such as supply and return lines from flange.

NOTE:

Press buttons on hose couplings to do this.

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.