Fuel Level Sensor: Service and Repair

Fuel Delivery Unit, Fuel Level Sensor And Suction Jet Pump

Special tools, testers and auxiliary items required
- Torque wrench (40 to 200 Nm) V.A.G 1332
- Wrench T10202

Requirements
- The fuel tank must be drained, emptying fuel tank
- Connectors and lines for left and right sensor flanges have been disconnected
- Locking rings for left and right sensor flanges have been removed

Removing
- Read safety precautions before beginning work.







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

NOTE: Press in securing ring to disengage the fuel lines.

- Remove sensor flange.







- Unclip black filler hose - arrow - from fuel delivery unit housing on left and right sides of fuel tank.







- Pull fuel supply line off fuel delivery unit - arrow - on left and right sides of fuel tank to suction jet pumps.
- Disconnect supply and return lines between both fuel delivery units on left side of fuel tank.
- Remove fuel delivery unit in bottom of fuel tank by turning approx. 90 degrees to left.

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

- Unclip fuel gauge sensors on both sides of fuel tank and pull them out.
- Unclip suction jet pumps from bottom on each side and remove with a slight turn.
- Pull out hose ends through left and right sensor openings.

Installing
Installation is in reverse order of removal, note the following:
- Connections for fuel lines must engage audibly when joined.
- Route fuel hoses kink-free.
- Ensure fuel hoses are seated securely.