Fuel Delivery Unit and Fuel Level Sensor

Fuel Delivery Unit and Fuel Level Sensor

Special tools, testers and auxiliary items required

• Wrench (T10202)

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

Requirements

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

Procedure

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

- Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.

- Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

- Fold the rear seat bench forward. On vehicles from 12.06, the rear seat bench must be removed.

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





- Remove the fuel delivery unit cover nuts - 1 - on the right side. It may be necessary to remove the backrest support - 2 - or the support mounting.





CAUTION!
The fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then release pressure by carefully disconnecting the connection.

- Disconnect the fuel supply line - 1 -, auxiliary heater fuel line - 2 -, fuel pump connector - 3 -, vent line - 4 - and fuel pump control module (J538) connector - 5 -.





• Press in the securing ring to disengage the lines.

- Remove the locking ring using the (T10202).





- Lift the flange.

- Disconnect the fuel pump connector - 1 - from the flange.





- Disconnect the fuel level sensor connector - 2 - from the flange.

- Disconnect the fuel supply line - 3 - from the flange.

• Press in the securing ring to disengage the line.

- Unclip the black filler hoses - 1 - from the fuel delivery unit housing.





- Disconnect the fuel line - 2 - from the suction jet pumps.

• Press in the securing ring to disengage the line.

- Remove the fuel line - 3 - from the fuel pump.

• To do this, press the red buttons on the hose coupling together.

• To do this, insert the assembly tool (T10118).

- Rotate the fuel delivery unit approximately 90° to the left and remove it from the bottom of the fuel tank.

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

- Unclip the fuel level sensor and remove.