Fuel Level Sensor 2 and Suction Jet Pumps

Fuel Level Sensor 2 and Suction Jet Pumps

Special tools, testers and auxiliary items required

• Wrench (T10202)

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

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

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

- Unclip the fuel level sensor 2 (G169) - 1 - and then remove it from the fuel tank.






- Press the tab - 1 -.






If you want to remove the suction jet pumps, proceed as follows:

- 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 lock 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 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 - off the fuel delivery unit housing.






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

• Press the locking ring to unlock the fuel line.

- Remove the retainer - 2 - for the suction jet pumps - 3 - on the left side of the fuel tank.






• The rear suction jet pump (- item 10 - in the => [ Fuel Delivery Unit, Fuel Level Sensor and Suction Jet Pumps Overview ] Fuel Delivery Unit, Fuel Level Sensor and Suction Jet Pumps Overview) cannot be seen in the illustration.

- Press the tab - 1 - to remove the suction jet pumps.






Remove the suction jet pumps together with the filler hoses and fuel pump fuel line from the left opening in fuel tank.

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.