Fuel Gauge Sender: Service and Repair

Fuel Delivery Unit, Fuel Gauge Sensor and Suction Jet Pump

Special tools, testers and auxiliary items required

• Torque wrench (40 to 200 Nm) (VAG 1332)

• Wrench (T10202)

Requirements

• The fuel tank must be drained. Refer to --> [ Fuel Tank Draining ] Procedures.

• Connectors and lines for left and right sender flanges have been disconnected.

• Locking rings for left and right sender flanges have been removed.

Removing

- Read safety precautions before beginning work. Refer to --> [ Safety Precautions ] Service Precautions.

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





• 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 the fuel delivery unit in bottom of fuel tank by turning it approximately 90 degrees to the left.

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

- Unclip fuel gauge senders 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 performed in the reverse order of removal, noting the following:

• Connections for fuel lines must engage audibly when joined.

• Route the fuel hoses kink free.

• Ensure fuel hoses are seated securely.