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Fuel Delivery Unit/Fuel Level Sensor: Removing

CAUTION:

Conditions 

  • The fuel tank may be a maximum of 3/4 full. This ensures the fuel level is below the fuel delivery unit flange.
NOTE:

Drain the fuel tank using the fuel extracting device.

Follow all safety precautions, refer to SAFETY PRECAUTIONS .

Follow the guidelines for clean working conditions, refer to FUEL SYSTEM CLEAN WORKING CONDITIONS .

Fuel tank and attachments overview, refer to one of the following:

Front Wheel Drive (FWD), refer to FUEL TANK AND ATTACHMENTS OVERVIEW .

All Wheel Drive (AWD), refer to FUEL TANK AND ATTACHMENTS OVERVIEW .

Drain the fuel tank, refer to FUEL TANK, DRAINING .

-- Remove the rear seat bench or fold it up, refer to "Rear Seats" in Removal and Installation .

-- Remove the carpet and fold it upward.

-- Remove the right cover and the fuel pump control module -2- from the opening above the fuel delivery unit.

Fig 1: Identifying Cover With Fuel Pump Control Module J538
GWWN20-0603Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the right cover -1- using the Trim Removal Wedge 3409 at the tabs -arrows-.

Fig 2: Identifying Right Cover
GWWA20-10835Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -1-.

Fig 3: Identifying Connector -1-, Fuel Line -2- And Fuel Delivery Unit -3-
GWWN20-10828Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
WARNING:

The fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Open the connection carefully and release the pressure.

-- Disconnect the fuel line -2- from the fuel delivery unit flange -3-. Disconnect the coupling, refer to COUPLING, DISCONNECTING .

NOTE:

Pay attention to the installed position of all the components.

-- Remove the lock ring using the Wrench - Fuel Sending Unit T10202 and lift the flange slightly.

Fig 4: Identifying Removal Of Locking Ring Using Wrench T10202
GWWN20-10645Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
CAUTION:

Do not bend the Wrench - Fuel Sending Unit T10202 and push hard on the locking ring. If the wrench slides down, the fuel delivery unit can be damaged.

-- Remove the fuel delivery unit flange from the opening in the fuel tank as far as possible.

Fig 5: Identifying Installation Of Flange On To Delivery Unit
GWWN20-10177Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the seal -A- from the fuel tank and pull it above the flange.

Fig 6: Identifying Sealing Ring Pulled Over Flange
GWWN20-10178Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Front Wheel Drive (FWD)

Fig 7: Identifying Fuel Delivery Unit Without Flange
GWWN20-10827Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

Ignore -1-.

-- Disconnect the coupling -2-, refer to COUPLING, DISCONNECTING .

All Wheel Drive (AWD)

Fig 8: Disconnecting/Connecting Fuel Lines
GWWN20-10240Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Release the suction jet pump -B- at the clips -arrows- and remove it.

-- Disconnect the coupling -A-, refer to COUPLING, DISCONNECTING .

Continuation for All

-- Remove the delivery unit through the fuel tank opening.

NOTE:

Drain the delivery unit before if it is going to be replaced.

Follow all disposal regulations.

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