Fuel level sensor, removing and installing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Vehicles with all-wheel drive have two fuel level sensors. How to remove the Fuel Level Sensor 2 G169, refer to Suction jet pump, removing and installing .
Empty fuel tank using fuel siphoning unit VAS 5190.

Removing

CAUTION: Fuel system is under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

Remove fuel delivery unit, refer to Fuel delivery unit, removing and installing .

Fig 1: Fuel Gauge Sender Connectors & Retaining Tabs

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Release and pull off terminals for wires - 3 - and - 4 -.
Lift retaining tabs - 1 - and - 2 - with a screwdriver and pull fuel level sensor G downward and off - arrow -.

Installing

Insert fuel gauge sender G into the guides on the fuel delivery unit and push up until it engages.
When installing, verify that the seals for the sensor flange are correctly seated.

NOTE:

If seals are swollen with fuel, always replace.
Moisten seal with fuel only when installing fuel delivery unit and fuel level sensor 2.