Removing and installing fuel delivery unit and fuel gauge sender G — VW

Removing and installing
fuel delivery unit and fuel gauge sender
G
Special tools and workshop equipment required
Special wrench
T10202
Torque wrench
V.A.G 1332
Not illustrated:
Assembly tool
T10118
Procedure:
Note
Attach all cable ties in the same places when installing.
Note safety precautions before starting installation work
Chapter
.
Observe rules for cleanliness
Chapter
.
Remove rear seat bench
General body repairs, interior
Rep. gr.
72
Removing and installing seat bench
.
On left side, remove flange with fuel filter
Chapter
.
Then, fold right-hand carpet cut-out to the side.
Remove securing nuts
1...4
of flange cover.
Remove flange cover.
Detach breather line
1
.
Note
Release connection by pressing button on line coupling.
WARNING
The fuel supply line is under pressure.
Risk of eye and skin injury from fuel.
Wear eye protection and protective clothing to avoid eye injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully opening the connection point.
Hold a cleaning cloth on connection of fuel supply line
2
and pull off hose coupling.
Note
Release connection by pressing button on line coupling.
Disconnect connector
3
from fuel gauge sender and connector
4
for fuel pump.
Use
special socket
T10202
to unscrew locking ring from sender flange.
Carefully raise the sender flange.
Draw off fuel, if necessary
Chapter
Pull connector
1
of fuel pump off flange.
Pull connector
2
for fuel gauge sender off flange.
Remove sender flange.
To do this, pull out sender flange together with fuel line of fuel filter out of right opening of fuel tank.
Unclip black supply/filler hose
1
and
2
from fuel delivery unit housing.
Detach fuel supply line
3
for suction-jet pumps.
Note
Press in securing ring to release fuel line.
Pull fuel return line
4
off fuel filter / fuel pump.
Note
Press red button on coupling together for this.
Use
assembly tool
T10118
for this.
Unscrew fuel delivery unit in bottom of fuel tank by turning approx. 15° to left.
Note
The fuel pump housing is filled with fuel. Fuel may run out if housing is tipped or canted.
Unclip and pull out fuel gauge sender.
Installing:
Installation is carried out in the reverse order. When installing, note the following:
First renew seals of sender flanges.
Insert flange in direction of travel
arrow
.
Lug of flange
2
must stay between tabs
1
and
3
of fuel tank.
Use
special socket
T10202
to tighten locking ring to 145 Nm.
Note
Ensure that connectors and fuel hose connections are fitted securely.