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 (40-200 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.

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

- Unclip the fuel level sensor and remove it.

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

- 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 (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.

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

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