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.