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

-- If possible, read and note the fuel level in the fuel tank.

-- Switch off the ignition.

-- Remove the installation opening cover. Refer to INSTALLATION OPENING COVER, REMOVING AND INSTALLING .

-- Release and remove the connector -arrow- from the sealing flange.

Fig 1: Fuel Pump Control Module Connector

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-- Remove the Fuel Pump Control Module -J538- with the connected wiring harness. Refer to Fuel Pump Control Module -J538-, REMOVING AND INSTALLING .

-- 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

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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.

Vehicles with Parking Heater:

-- Remove the fuel line -2- to the Metering Pump -V54- for the parking heater on the sealing flange. Refer to If the fuel line for the is removed from the fuel delivery unit: .

Continuation for All Vehicles:

Fig 3: Identifying Fuel Sending Unit Wrench

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-- Open the locking ring using the Wrench - Fuel Sending Unit:T10202 .

-- Carefully lift the fuel delivery unit sealing flange.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Guide the fuel line out between the sealing flange and the delivery unit.

-- Carefully remove the fuel delivery unit with both lines -3- and -4- as much as possible out of the fuel tank opening.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- At the same time turn and tilt the corresponding fuel delivery unit.

-- 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.

-- Push the release buttons -arrow A- on the connecting piece -2-.

-- Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Remove the line -3- from the line -1-.

-- Pull the locking mechanism -arrow B- upward.

-- To do this, push the locking mechanism and pull the slider upward.

-- Remove the line -4-.

NOTE:

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

Follow all waste disposal regulations.

Check the fuel tank for contamination.