Fuel Filter: Service and Repair

Suction Jet Pump, Fuel Filter and Pressure Relief Valve

Special tools, testers and auxiliary items required

• Wrench (T10202)

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

• On All Wheel Drive (AWD) vehicles, the fuel must be pumped out of the fuel level sensor 2 area and to the fuel delivery unit due to the shape of the fuel tank. A suction jet pump, pumps the fuel from the left chamber to the right chamber in the fuel tank.

• The fuel delivery unit must be removed first, in order to remove the suction jet pump.

• The left flange consists of the suction jet pump, fuel filter, pressure relief valve and fuel level sensor 2. Only the fuel level sensor 2 can be replaced separately.

• Only check the fuel level sensor 2 if the engine shuts off due to low fuel but the fuel gauge indicates the tank is still 1/4 full.

Removing

- Remove the rear seat bench.

- Remove the fuel delivery unit. Refer to => [ Fuel Delivery Unit ] Fuel Delivery Unit.

- Remove left cover (when viewed from the direction of travel) from the fuel level sensor 2.

- First, pull on the connector without pressing the retainer to make sure it is connected securely. If the connector was not connected correctly, it could cause a fault.

- Disconnect the connector - 1 - from the left flange.






- Remove the lock ring using the wrench (T10202).






- Lift the flange slightly and remove the seal from the fuel tank opening.

- Remove the flange from the fuel tank together with the fuel level sensor 2.

- Check the fuel lines for kinks and damage.

- Check the suction jet pump and the fuel tank for any contamination.

Installing

Do not bend the fuel level sensor 2 float arm when installing.

- Insert the flange in the fuel tank together with the fuel level sensor 2. The tab on the flange faces in the direction of travel.

- Route the fuel lines in the right chamber of the fuel tank so they are not kinked.

- Insert a new, dry seal into the fuel tank opening. Only coat the inner side that comes into contact with the flange with fuel.

- Note the fuel level sensor 2 installed position. Refer to => [ Installed Position of the Fuel Delivery Unit Flange and Fuel Level Sensor 2 ] Fuel Tank and Attachments Overview.

- Make sure the seal is in the correct location.

- Install the lock ring using the wrench (T10202). Tightening specification: 110 Nm.






- Connect the connector - 1 - and pull on it to make sure it is connected securely.






- Install the fuel delivery unit. Refer to => [ Fuel Delivery Unit ] Fuel Delivery Unit.

The rest of the installation follows the reverse of the removal procedure.