Fuel Level Sensor: Service and Repair

Fuel Pump (FP) unit, fuel level sensor and suction jet pumps, removing and installing
Special tools, testers and auxiliary items required





^ Polydrive key T10202
^ Torque wrench VAG 1332

Requirements
^ Fuel tank must be empty, Fuel tank, emptying.
^ Connector and wiring of sensor flanges, right and left, are disconnected.
^ Seals of sensor flanges, right and left, are unscrewed.

Work sequence
- Read safety precautions. Refer to safety precautions




- Disconnect harness connectors - 1 - and - 2 -, and hose couplings - 3 -, - 4 - and - 5 - below right sensor flange.
- Remove sensor flange.






- Unclip black fill hose - arrow - from Fuel Pump (FP) unit housing on right and left side of fuel tank.





- Disconnect supply line on right and left side of fuel tank, at Fuel Pump (FP) unit - arrow - to suction jet pumps.
- Disconnect supply and return lines between both fuel delivery units on left side of fuel tank.
- Unbolt Fuel Pump (FP) unit bolted to fuel tank floor approximately 90° to left.

Note:
^ Fuel pump (FP) unit housing is filled with fuel. Tilting it can cause fuel to overflow.

- Unclip fuel level sensors on both sides of fuel tank and remove them.
- Suction jet pumps on both sides can be unclipped from floor and removed by rotating them slightly.
- Pull out both hose ends through left or right opening of sensor.