Fuel Delivery Unit and Fuel Level Sensor

Fuel Delivery Unit and Fuel Level Sensor

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Assembly Tool (T10118)

Removing

• During installation, all cable ties must be installed at the same location.

- Read the safety precautions before starting. Refer to => [ Safety Precautions ] Safety Precautions.

- Follow the rules of cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

- Remove the rear seat bench.

- Remove the fuel filter flange from the left side of the tank. Refer to => [ Fuel Filter ] Service and Repair.

- Fold the right carpet to the side.






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

- Remove the flange cover.

- Disconnect the vent line - 1 -.






• Squeeze the buttons on the line couplings.

The fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective goggles and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Open the connection carefully and release the pressure.

- Place a cloth around the fuel supply line connection - 2 - and remove the hose coupling.

• Squeeze the buttons on the line couplings.

- Disconnect the connector - 3 - from the fuel level sensor and the connector - 4 - from the fuel pump.

- Remove the locking ring from the sensor flange using the wrench (T10202).






- Carefully lift the sensor flange.

- Siphon the fuel out, as necessary. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

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






- Disconnect the fuel level sensor connector - 2 - from the flange.

- Remove the sensor flange.

- Remove the sensor flange with the fuel filter fuel line through the right opening in the fuel tank.

- Unclip the black filler hoses - 1 and 2 - from the fuel delivery unit housing.






- Remove the fuel line - 3 - for the suction jet pumps.

• Squeeze the buttons on the line couplings

- Remove the connecting line - 4 - from the fuel filter/fuel pump.

• To do this, press the red buttons on hose coupling together.

• Use the assembly tool (T10118) for this.

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

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

- Remove the fuel level sensor.

Installing

Installation is carried out in the reverse order while noting the following:

- Replace the seals for the sensor flanges.

- Install the flanges in the direction of travel - arrow -.






The tab on the flange - 2 - must be between the tabs - 1 and 3 - on the fuel tank.

- Tighten the lock ring to 145 Nm using the wrench (T10202).






• Make sure the connectors and the fuel hoses are secure.