Fuel Level Sensor: Service and Repair

Fuel Level Sensor And Suction Jet Pumps, Removing And Installing


Special tools, testers and auxiliary items required







- Wrench T10202







- Torque wrench (40 to 200 Nm) V.A.G 1332

Requirements
- The fuel tank must be drained, emptying fuel tank.

Work procedure

NOTE: All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

- Read safety precautions before beginning work.
- Observe rules for cleanliness.
- Remove flange with fuel filter on left side of fuel tank, replace fuel filter.
- Now unclip fuel level sensor and remove it.

If you want to remove suction jet pumps, proceed as follows:
- Fold rear seat bench forward. On vehicles from 12.2006, rear seat bench must be removed.







- Cut open carpet on right side from point - A - to point - B - in pre-cut area - arrow - .







- Remove nuts - 1 - on right side of fuel delivery unit cover. If necessary, remove backrest support - 2 - or mounting bracket.

CAUTION: Fuel supply lines are under pressure. Wear protective goggles and protective gloves to avoid damage and contact with skin. Before removing from hose connection wrap a cloth around connection. Then release pressure by carefully pulling hose off connection.







- Remove fuel supply line - 1 - , auxiliary heater fuel line - 2 - , fuel pump connector - 3 - , vent line - 4 - and Fuel Pump (FP) Control Module J538 connector - 5 - .

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







- Remove locking ring from sensor flange using wrench T10202.
- Lift sensor flange.







- Disconnect fuel pump connector - 1 - from flange.
- Remove fuel level sensor connector - 2 - from flange.
- Disconnect fuel supply line - 3 - to sensor flange.

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







- Unclip black filler hoses - 1 - from fuel delivery unit housing.
- Disconnect fuel line - 2 - from suction jet pumps.

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

- Now unclip suction jet pumps on left side of fuel tank.

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