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Fuel Gauge Sender: Service and Repair






Fuel Delivery Unit, 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 ] Procedures.

Connectors and wires for left and right flanges have been disconnected.

The locking rings for the right and left flanges have been removed.

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

Removing

- Disconnect the connectors - 1 and 2 - and the hose couplings - 3, 4 and 5 - under the right flange.





- Remove the flange.

- Unclip the black filler hose - arrow - from fuel delivery unit housing on the left and right sides of the fuel tank.





- Remove the supply line to the suction jet pumps at the fuel delivery unit - arrow - on the right and left sides of the fuel tank.





- Disconnect the supply and return lines between both fuel delivery units on the left side of the fuel tank.

- 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 sensors on each side of fuel tank and pull them out.

- Unclip the suction jet pumps from the bottom on each side and remove them with a slight turn.

- Pull out the hose ends through left and right tank openings.

Installing

- Installation is performed in the reverse order of removal.