Removing and installing fuel gauge sender 2 G169 and suction-jet pump — VW

Removing and installing
fuel gauge sender 2
G169
and suction-jet pump
Special tools and workshop equipment required
Special wrench
T10202
Torque wrench 40-200 Nm
V.A.G 1332
Removing:
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
.
Remove flange with fuel filter on left side of fuel tank
Chapter
.
Extract fuel if necessary
Chapter
.
Unclip
fuel gauge sender 2
G169
1
and pull out of fuel tank.
To do this, press locking lug
1
.
Proceed as follows if the suction-jet pumps are to be removed:
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 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.
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 sender flange.
Extract 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
from suction-jet pumps.
Note
Press in securing ring to release fuel line.
On the left side of the fuel tank, unclip bracket
2
of suction-jet pumps
3
.
Note
The rear suction jet pump
Item
is not visible in the illustration.
To remove suction-jet pump, press locking lug
1
.
Pull suction-jet pumps together with supply/filler hoses and fuel lines out of left opening of fuel tank.
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 flanges
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.