Fuel Delivery Unit/Fuel Level Sensor, Removing And Installing

Special tools and workshop equipment required

Wrench - Fuel Sending Unit: T10202
Torque Wrench 1332 40-200Nm: VAG1332

Conditions

The fuel tank must be empty. Refer to FUEL TANK, DRAINING .
The connectors and wires for left and right sensor flanges have been removed.
The locking rings for the right and left sensor flanges have been removed.

Procedure

-- Remove the rear bench seat. Refer to BENCH SEATS, REMOVING AND INSTALLING .

-- Fold the right carpet cut-out to the side.

Fig 1: Identifying Locking Flange Cover - Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the nuts -1 through 4- on the flange cover.

-- Remove the flange cover.

-- Lift up the right sensor flange.

-- Disconnect the fuel pump connector -1- from flange.

Fig 2: Fuel Pump Connector -1-, Fuel Level Sensor Connector -2-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the connector -2- for the Fuel Gauge Sensor -G- from the flange.

-- Unclip the black filling hose -arrow- from the fuel delivery unit housing on the right side of the fuel tank.

Fig 3: Fuel Delivery Unit Housing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the supply line -arrow- to the suction jet pump on the right side of the fuel tank. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 4: Supply Line -Arrow-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Rotate the fuel delivery unit approximately 15° to the left and remove it from the bottom of the fuel tank.

NOTE:

The fuel delivery unit housing is filled with fuel. Fuel may run out if the housing is tipped or tilted.

-- Unclip the Fuel Gauge Sensor -G- on the right -item ) OVERVIEW - FUEL DELIVERY UNIT/FUEL LEVEL SENSOR - List Item: Fuel Level Sensor -G-.

-- Lift up the left sensor flange.

-- Remove the connector -arrow- for the Fuel Level Sensor 2 -G169- from the flange.

Fig 5: Fuel Level Sensor

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip the Fuel Level Sensor 2 -G169- on the left side -1- and the bracket -2- for the suction jet pumps -3-.

Fig 6: Fuel Level Sensor -1-, Retainer -2, Suction Jet Pumps -3-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The suction jet pump -item ) OVERVIEW - FUEL DELIVERY UNIT/FUEL LEVEL SENSOR - List Item: Suction Jet Pump cannot be seen in the illustration.

-- Remove both suction jet pumps by turning lightly.