Fuel Delivery Unit/Fuel Level Sensor, Removing And Installing: Notes

Special tools and workshop equipment required

Wrench - Fuel Sending Unit :T10202
Torque Wrench 1332 40-200Nm :VAG1332
Trim Removal Wedge :3409

Removing

-- Pay attention to the safety precautions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS ON PARKING/AUXILIARY HEATER AND FUEL SYSTEM .

CAUTION:

Electrical components could be damaged when disconnecting the battery.

Follow the steps for disconnecting the battery.

-- Disconnect the ground cable from the battery terminal. Refer to BATTERY, DISCONNECTING AND CONNECTING .

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

-- Drain the fuel tank. Refer to FUEL TANK .

-- Remove the rear bench seat. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

-- Unclip the sealing flange cover -1- at the tabs in direction of -arrows- using the :3409 .

Fig 1: Fuel Pump Cover (Under Rear/Bench Seat)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip the grommet -1- downward out of the cover -2-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Guide the cover -2- on the wiring harness -3- toward the rear.

-- Unlock and disconnect the connector -1- from the sealing flange.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If equipped, disengage the connector -2- for the parking heater Metering Pump -V54- on the sealing flange and move it to the side.

-- Remove the fuel line -1- from the sealing flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 2: Fuel Lines to the Fuel Delivery Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- If equipped, remove the fuel line -2- to the Metering Pump -V54- for the parking heater on the sealing flange.

-- Loosen the lower hose clamp to do this.

-- Open the locking ring using the :T10202 .

Fig 3: Identifying Fuel Sending Unit Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully lift the fuel delivery unit flange.

-- Pull the sealing flange -2- out of the opening in the fuel tank just a little.

Fig 4: Identifying Locking Flange & Seal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the seal -1- at the fuel tank opening.

-- Carefully pull the fuel delivery unit with the Fuel Gauge Sensor -G- out through the fuel tank opening.

-- Turn and tilt it as needed.

-- Be careful not to bend the floater arm on the fuel level sensor when removing the fuel delivery unit.

-- Place a cloth underneath to catch the leaking fuel, since the fuel delivery unit is still filled.

Vehicles with Suction Line in the Fuel Tank:

-- Pull the fuel delivery unit -2- as far as possible out of the fuel tank.

Fig 5: fuel delivery unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Release the fuel line -1- in the fuel tank and disconnect it from the suction line -3-. Connector Couplings, Disconnecting. Refer to CONNECTOR COUPLINGS .

Continuation for All Vehicles

NOTE:

If the delivery unit is being replaced, the old delivery unit must be emptied before disposing of it.

Follow all waste disposal regulations.

Check the fuel tank for contamination.