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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Fuel Pump Control Module -J538-
   • Check using the Vehicle Diagnostic Tester .
   • Refer to Fuel Pump Control Module -J538-, REMOVING AND INSTALLING 
2. Connector
   • For Fuel Pump Control Module -J538-
3. Connector
   • For Transfer Fuel Pump -G6-
4. Connector
   • For Fuel Level Sensor -G- and Fuel Level Sensor 2 -G169-
5. Locking Ring
   • Loosen and tighten using the Wrench - Fuel Sending Unit: T10202 
   • 110 Nm
6. Sealing Flange
   • Refer to Fuel Level Sensor 2 -G169-, REMOVING AND INSTALLING 
7. Seal
   • Replace after removing
   • Install dry
8. Fuel Level Sensor 2 -G169-
   • Check eclectically using the Vehicle Diagnostic Tester .
   • Refer to Fuel Level Sensor 2 -G169-, REMOVING AND INSTALLING 
9. Mount with Suction Jet Pump
   • No replacement part
   • Welded to the fuel tank
   • Function. Refer to SUCTION JET PUMP, REMOVING AND INSTALLING .
10. Fuel Level Sensor -G-
    • Check eclectically using the Vehicle Diagnostic Tester .
    • Refer to Fuel Level Sensor -G-, REMOVING AND INSTALLING 
11. Fuel Delivery Unit
    • With the Transfer Fuel Pump -G6-
    • With integrated fuel filter; the fuel filter cannot be replaced separately
    • Removing and Installing. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .
12. Seal
    • Replace after removing
    • Install dry
13. Locking Ring
    • Loosen and tighten using the Wrench - Fuel Sending Unit: T10202 
    • 110 Nm
14. Fuel Line
    • To the engine
    • Do not kink

Overview - Fuel Delivery Unit/Fuel Level Sensor, Vehicles with Parking Heater: 

Fig 2: Exploded View Of Fuel Delivery Unit/Fuel Level Sensor (Vehicles With Parking Heater)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Fuel Delivery Unit
   • With the Transfer Fuel Pump -G6-
   • With integrated fuel filter; the fuel filter cannot be replaced separately
   • Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING 
2. Clamp
   • Replace after removing
   • Secure the hose connections with hose clamps that correspond to the model.
3. Clamp
   • Replace after removing
   • Secure the hose connections with hose clamps that correspond to the model.
4. Fuel Line
   • To the Metering Pump -V54-
   • Refer to PARKING/AUXILIARY HEATER FUEL LINE, REMOVING AND INSTALLING 
5. Grommet
   • Check for damages
6. Fuel Line
   • To the engine

Fuel Delivery Unit Installation Position

Fig 3: Fuel Delivery Unit Installation Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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