Fuel Delivery Unit/Fuel Level Sensor

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

After removing the fuel delivery unit, check the fuel tank for visible contamination and clean if necessary.

Special tools and workshop equipment required

Wrench T10202
Torque Wrench (40-200 Nm) V.A.G 1332

Removing

CAUTION:

Conditions:

The fuel tank may be a maximum of 3/4 full. This ensures the fuel level is below the fuel delivery unit flange.

NOTE:

Drain the fuel tank using the fuel extracting device VAS 5190, if necessary.

Read the safety precautions before starting. Refer to SAFETY PRECAUTIONS .

Pay attention to the rules of cleanliness. Refer to CLEAN WORKING CONDITIONS .

Fuel tank overview. Refer to FUEL TANK AND ATTACHMENTS OVERVIEW .

-- Remove the rear seat bench. Refer to "Rear Seats" in Removal and Installation .

-- Remove the cover -1- and fuel pump control module -J538- -2- from the fuel delivery unit.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

-- Disconnect the connector -arrow-.

Fig 2: Identifying Fuel Pump Control Module Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the fuel lines -1 and 2- from the flange. Disconnecting the couplings, refer to COUPLING, DISCONNECTING .

Fig 3: Identifying Fuel Lines At Flange

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-- Remove the lock ring using the wrench T10202 and raise the flange slightly.

Fig 4: Identifying Locking Ring And Wrench T10202

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-- Pull the delivery unit and seal out of the fuel tank opening.

NOTE:

If the delivery unit is to be replaced then drain the old delivery unit before disposal.

Follow disposal regulations.

Installing

-- Replace the seal.

-- Install the seal into the opening in the fuel tank dry.

-- Coat the inner side of the seal with fuel.

-- When installing the fuel delivery unit, be sure not to bend the fuel level sensor arm.

-- Press the flange down and bring it into the installed position.

Fig 5: Fuel Delivery Unit, Installed Position

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The tab -2- on flange must lie between tabs -1 and 3- on the fuel tank.
The -arrow- points in the direction of travel.

-- Install the lock ring.

Tightening specification: 110 Nm

-- Connect the supply line -1- (black).

Fig 6: Identifying Fuel Lines At Flange

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the return line -2-. It is blue or has a blue mark.

-- Connect the connector -arrow-.

Fig 7: Identifying Fuel Pump Control Module Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull on the couplings and connector to make sure they are fastened securely.

The rest of the installation is performed in the reverse order of removal. Note the following:

The -arrow- on the cover points in the direction of travel.

Fig 8: Identifying Direction Of Arrow On Cover
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.