Fuel Level Sensor: Service and Repair

Fuel Delivery Unit and Fuel Level Sensor

Special tools, testers and auxiliary items required

• Wrench (T10202)

• Torque wrench (40 to 200 Nm) (VAG 1332)

Requirements

• The fuel tank must be drained. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

Procedure

• All cable ties which are opened or removed when removing, must be replaced in the same position when installing.

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

- Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

- Fold rear seat bench forward. On vehicles from 12.06, rear seat bench must be removed. Refer to

- Cut open the carpet on the right side from point - A - to point - B - in the precut area - arrow -.





- Remove the nuts - 1 - from the right side fuel delivery unit cover. If necessary, remove backrest support - 2 - or mounting bracket.





CAUTION!
Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before disconnecting connection, wrap a cloth around the connection. Then release pressure by carefully separating connection.

- Remove fuel supply line - 1 -, auxiliary heater fuel line - 2 -, fuel pump connector - 3 -, vent line - 4 - and Fuel Pump (FP) control module (J538) connector - 5 -.





• Press in securing ring to disengage the fuel line.

- Remove locking ring from flange using wrench (T10202).





- Lift flange.

- Disconnect fuel pump connector - 1 - from flange.





- Remove fuel level sensor connector - 2 - from flange.

- Disconnect fuel supply line - 3 - from flange.

• Press in securing ring to disengage the fuel line.

- Unclip black filler hoses - 1 - from fuel delivery unit housing.





- Disconnect fuel line - 2 - from suction jet pumps.

• Press in securing ring to disengage the fuel line.

- Remove fuel line - 3 - from fuel pump.

• To do this, press red buttons on hose coupling together.

• To do this, insert assembly tool (T10118).

- Remove the fuel delivery unit from the bottom of fuel tank by turning it approximately 90 degrees to the left.

• The fuel delivery unit housing is filled with fuel. Fuel may spill out if the housing is tipped or tilted.

- Unclip fuel level sensor and remove.