Removing and installing fuel delivery unit/fuel gauge sender, vehicles with union nut — VW

🧭 Before you start

Drain the tank, disconnect the battery earth and remove the rear bench and access cover. Unplug the connector, release fuel pressure and disconnect the line, then open the union nut with the special tool and withdraw the unit with care. Check the tank for dirt, fit a new seal dry and wet its inner face with fuel, refit the unit, press the flange into position and tighten the nut, then reconnect and pull-test the lines.

Fits: platform code 121

• Opens: fuel
• Renewed: seal

Don't miss

• The fuel line is under pressure; wear eye protection and wrap a cloth around the joint.
• Do not bend the sender float arm on the way out or in.
• Renew the seal; insert it dry, then coat its inner side with fuel.
• Press the flange down against spring force into its installation position before tightening the union nut.
• Look into the tank for dirt or debris while it is open.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📐 36 workshop diagrams for CHYA

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Drain fuel tank .
2. Disconnect battery earth Electrical system27Battery; Disconnecting and connecting battery.
3. Remove rear bench seat General body repairs, interior72Rear seat; Removing and installing bench seat / individual seats.
4. Unclip cover (1) at retaining tabs (arrows) using removal wedge3409.
5. Release and pull off connector (1).

6. ⚠ The fuel line is under pressure.Risk of injury to eyes and skin 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. — Release and disconnect fuel lines (2) from fuel delivery unit (3). Separate plug-in connectors .
7. Loosen union nut with union nut tool3217.
8. Pull sealing flange out of the opening in fuel tank.
9. Remove seal from opening in fuel tank.
10. Place a cloth underneath to absorb fuel.
11. Pull fuel extraction unit (1) with fuel gauge sender out through the installation opening of the fuel tank carefully.
12. When removing the fuel delivery unit, ensure that the float arm of the fuel gauge sender G is not bent.
13. Check fuel tank for foreign bodies and dirt. [Note: If delivery unit is to be renewed, old delivery unit must be drained before disposal.Observe environmental regulations for disposal.]
14. Renew seal.
15. Insert seal for fuel delivery unit dry into opening of fuel tank.
16. Coat inner side of seal with fuel.
17. When inserting fuel delivery unit, ensure that fuel gauge sender is not bent.
18. Press down sealing flange (3) against spring force.
19. Move sealing flange into installation position .
20. Tighten union nut.
21. Reconnect connector (1).
22. Push on fuel line (2).
23. Ensure plug-in connector and connector are secured properly by pulling.

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