Removing and installing fuel delivery unit/fuel gauge sender, version 2 — VW

🧭 Before you start

Fits: VW Touran I (1T, 2003–2015)

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• Separate plug-in connectors .
• If delivery unit is to be renewed, drain old delivery unit before disposal.

🔧 Engine codes this applies to

📐 80 workshop diagrams for CAYB

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

📋 Procedure

1. First check whether a coded radio is fitted. If so, obtain anti-theft coding.
2. Disconnect earth strap from battery with ignition switched off Electrical system27Battery; Disconnecting and reconnecting battery.
3. Remove the right and centre seats of the second row of seats.General body repairs, interior72Rear seat; Removing and installing bench seat / individual seats .
4. Detach carpet under seats and fold it back. General body repairs, interior70
5. Lever out cover upwards.

6. Remove cover of fuel delivery unit.
7. Pull 5-pin connector and fuel lines off flange. [Note: Separate plug-in connectors .]
8. ⚠ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!Wear eye and hand protection when performing any type of repair work on the fuel system! — Unscrew union nut with union nut tool3217wrench.
9. Pull fuel delivery unit and seal out of the opening in fuel tank. [Note: If delivery unit is to be renewed, drain old delivery unit before disposal.]
10. Installing the fuel delivery unit is carried out in reverse order of removal. [Note: Do not bend fuel gauge sender when installing.Insert seal for flange or fuel delivery unit dry into opening of fuel tank.Moisten seal with fuel only when installing flange or fuel delivery unit.Ensure that fuel hose connections are tight.After installing fuel delivery unit, check that the supply, return and breather lines are still clipped onto the fuel tank.Note installation position of fuel delivery unit flange: mark on flange must align with mark on fuel tank (arrows).]

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