Fuel Level Sensor and Suction Jet Pumps

Fuel Level Sensor and Suction Jet Pumps

Special tools, testers and auxiliary items required

• Wrench (T10202)

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

Requirements

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

Procedure

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

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

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

- Remove the flange with fuel filter from the left side of the fuel tank. Refer to => [ Fuel Filter ] Removal and Replacement.

- Now unclip fuel level sensor and remove it.

If you want to remove the suction jet pumps, proceed as follows:

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

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





- Remove the nuts - 1 - from the right side fuel delivery unit cover. If necessary, remove backrest support - 2 - or mounting bracket. Refer to





CAUTION!
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 separating the 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 -.





• Press in securing ring to disengage the fuel line.

- Remove locking ring from flange using wrench (T10202).





- Lift flange.

- Disconnect fuel pump connector - 1 - from flange.





- Remove fuel level sensor connector - 2 - from flange.

- Disconnect fuel supply line - 3 - from flange.

• 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.

• Press in securing ring to disengage the fuel line.

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

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