Fuel Delivery Unit/Fuel Level Sensor

Fuel Delivery Unit/Fuel Level Sensor

• After removing the fuel delivery unit, check the fuel tank for visible contamination and clean if necessary.

Special tools, testers and auxiliary items required

• Wrench (T10202)

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

• Trim Removal Wedge (3409)

Removing

Conditions

• The fuel tank may be a maximum of 3/4 full. This ensures the fuel level is below the fuel delivery unit flange.

• When replacing the fuel delivery unit, check the fuel tank for visible contamination and clean if necessary.

- Turn off the ignition and all electric consumers.

- Remove the key.

- Remove the rear seat bench.

- Remove the cover - 1 - from the fuel delivery unit using the trim removal wedge (3409) at the tabs - arrows -.






- Make sure the connector - 1 - is secure. If the connector was not connected correctly, it could cause a fault.






- Disconnect the connector - 1 -.

- Check the contacts on the connector and the fuel delivery unit for damage.

The fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Open the connection carefully and release the pressure.

- Disconnect the fuel line - 2 - from the fuel delivery unit flange - 3 - and wipe up any leaking fuel with a cloth. Refer to => [ Coupling, Disconnecting ] Service and Repair.






- Remove the lock ring using the wrench (T10202) and lift the flange up slightly.






• Pay attention to the installed position of all the components.

- Remove the fuel delivery unit flange from the fuel tank opening as far as possible.

- Remove the seal from the opening.

- Disconnect the coupling - 2 -. Refer to => [ Coupling, Disconnecting ] Service and Repair.






- Remove the suction jet pump intake line - arrows -.

- Remove the delivery unit out through the fuel tank opening.

• Drain the delivery unit, if it is going to be replaced.

• Follow all disposal regulations.

Installing

• Pay attention to the installed position of all the components.

Installation of the fuel delivery unit is performed in the reverse order of removal. Note the following:

- Replace the seal.

- Install the seal into the fuel tank opening dry.

- Coat the inner side of the seal with fuel.

- Install the fuel delivery unit. Be careful not to bend the fuel level sensor arm.

- Attach the suction jet pump intake line - arrows -.






- Connect the coupling - 2 -. Pull on the coupling to make sure it is secure.

- Make sure the flange - 1 - fits correctly on the fuel delivery unit.






- Press the flange downward against the spring force and move the flange into its installed position.






• The tab - 2 - on the flange must lie between tabs - 1 and 3 - on the fuel tank.

• The - arrow - points in the direction of travel.

- Install the lock ring.

- Connect the connector - 1 -.






- Connect the fuel line - 2 -.

- Pull on the coupling and connector to make sure they are fastened securely.

• The arrow on the cover - 2 - must point in the direction of travel.






Tightening Specification