Work procedure

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, 2004 Volkswagen Jetta, and 2004 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

Observe safety precautions before performing repair work. Refer to Safety precautions when working on fuel supply system .

NOTE:

To perform repair work, the Ground (GND) cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti-theft coding beforehand.

With ignition switched off disconnect battery Ground (GND) strap.
Remove cover under bench seat.

CAUTION:

The fuel or fuel lines in fuel system can become very hot (danger of scalding)!
In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!
Wear protective goggles and protective gloves when working on the fuel system!

Fig 1: Removing/Installing Union Nut With Wrench 3217

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect 4-pin connector and fuel hoses from fuel pump (right side of vehicle), and remove fuel pump. Refer to Fuel Pump (FP), removing and installing .

Fig 2: Removing/Installing Fuel Level Sensor 2 G169 Union Nut On Left Side Of Vehicle

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove fuel level sensor 2 G169 union nut on left side of vehicle.
Lift fuel level sensor 2 upward as far as possible.

Fig 3: Separating Cable Ties From Fuel Lines & Spreading Apart The Mount For Suction Jet Pump On Fuel Level Sensor 2

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate cable ties from fuel lines - arrow - and carefully spread apart the mount for suction jet pump on fuel level sensor 2.
Unclip and remove suction jet pump with supply and return lines on fuel level sensor 2.
Check that the fuel hoses/lines on suction jet pump are installed securely and are not damaged.
Check suction jet pump for contamination/dirt if necessary.

If no malfunctions are found:

Install suction jet pump and fuel level sensor 2 in reverse order.

NOTE:

Before installing the fuel pump and fuel level sensor 2, make sure that the seal is dry when setting into the fuel tank opening.
If seals are swollen with fuel, always replace.