Overview - Fuel Delivery Unit/Fuel Level Sensor, Fwd Vehicles

Fig 1: Exploded View Of Fuel Delivery Unit/Fuel Level Sensor, FWD Vehicles

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Fuel Delivery Unit
   • With the Transfer Fuel Pump -G6-
   • Cannot be replaced separately with an integrated fuel filter
   • Cannot be replaced separately with an integrated pressure relief valve
   • Check the fuel pump. Refer to Transfer Fuel Pump -G6-, CHECKING, EA888EVO  and Refer to Transfer Fuel Pump -G6-, CHECKING, EA211, EA211EVO, EA888 .
   • Removing and Installing. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .
   • Fill the vehicle with at least five liters of fuel after installing
   • Note the installation position. Refer to Fig 2.
2. Seal
   • Replace after removing
   • Install dry
3. Locking Ring
   • Loosen and tighten using the Wrench - Fuel Sending Unit:T10202 
   • 110 Nm
4. Fuel Pump Control Module -J538-
   • Check in Guided Fault Finding  using the Vehicle Diagnostic Tester.
   • Removing and Installing. Refer to Fuel Pump Control Module -J538-, REMOVING AND INSTALLING .
5. Connector
   • For Fuel Pump Control Module -J538-
   • Make sure it is attached securely and pull on it to make sure the connector it is properly locked.
6. Connector
   • For the Transfer Fuel Pump -G6- and the Fuel Level Sensor -G-
   • Make sure it is attached securely and pull on it to make sure the connector it is properly locked.
7. Fuel Supply Line
   • To the engine
   • Do not kink
   • To disconnect, press the release button on the connecting piece
   • The connector couplings must >>audibly<< engage when locking.
   • Pull on the connector coupling to check for secure fit.
   • Connector Couplings, Disconnecting. Refer to CONNECTOR COUPLINGS, DISCONNECTING .
8. Fuel Level Sensor -G-
   • Check using the Vehicle Diagnostic Tester.
   • Removing and Installing. Refer to Fuel Level Sensor -G-, REMOVING AND INSTALLING .

Fuel Delivery Unit Installation Position

Fig 2: Fuel Delivery Unit Installation Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Version 1:

• The arrow -3- on the fuel tank must point to the mark -2- on the sealing flange -1-.

Version 2:

Fig 3: Fuel Delivery Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• The tab -2- on sealing flange must lie between tabs -1- and -3- on the fuel tank.
• The -arrow- points in the direction of travel.

Fuel lines to the fuel delivery unit

Fig 4: Fuel Lines to the Fuel Delivery Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Fuel Supply Line
2. Fuel Line to Metering Pump -V54-