Fuel Delivery Unit/Fuel Level Sensor, Removing And Installing

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Wrench - Fuel Sending UnitT10202
Torque Wrench 1332 40-200NmVAG1332
Trim Removal Wedge3409

Removing

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

-- Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to PARKING/AUXILIARY HEATER AND FUEL SYSTEM CLEAN WORKING CONDITIONS .

-- Drain the fuel tank. Refer to FUEL TANK, DRAINING .

-- Remove the bench seat. Refer to REAR SEATS .

-- Unclip the locking flange cover -1- at the tabs -arrows- using the Trim Removal Wedge 3409.

Fig 1: Identifying Right Cover

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-- Disconnect the connector -arrow-.

Fig 2: Fuel Pump Control Module Connector

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-- Remove the fuel lines -1- and -2- from the flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 3: Fuel Lines At Flange

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WARNING:

Fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose connections. Open the connection carefully and release the pressure.

NOTE:

If the vehicle has an auxiliary heater, then disconnect the fuel line connector from the Metering Pump -V54-. .

-- Open the locking ring using Wrench - Fuel Sending Unit T10202 and lift the flange slightly.

Fig 4: Identifying Locking Ring And Wrench T10202

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CAUTION:

Do not bend the Wrench - Fuel Sending Unit T10202 and push hard on the locking ring. If the wrench slides down, the fuel delivery unit can be damaged.

-- Remove the fuel delivery unit -1- and the gasket from the opening in the fuel tank.

Fig 5: Identifying Fuel Delivery Unit

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NOTE:

Drain the delivery unit before if it is going to be replaced.

Follow all disposal regulations.

Check the fuel tank for contamination.

Installing:

Install in reverse order of removal. Note the following:

-- Replace the seal if damaged.

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

-- Coat the inner side of the sealing ring with fuel.

-- Be careful not to bend the fuel gauge sensor when installing the fuel delivery unit.

-- Pay attention to the installed position of the fuel extraction line for the auxiliary heater. .

-- Press the locking flange downward against the spring force and move the locking flange into its installed position.

Fig 6: Fuel Delivery Unit, Installed Position

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

-- Tighten the locking ring using the Wrench - Fuel Sending UnitT10202.

Fig 7: Identifying Locking Ring And Wrench T10202

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CAUTION:

Do not bend the Wrench - Fuel Sending UnitT10202 and push hard on the locking ring. If the wrench slides down, the fuel delivery unit can be damaged.

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

Fig 8: Fuel Lines At Flange

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

-- Do not interchange supply and return lines (return line blue or with blue markings, supply line black).

-- Make sure the line connections are securely fastened.

-- Connect the connector -arrow-.

Fig 9: Fuel Pump Control Module Connector

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

NOTE:

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

Fig 10: Identifying Cover Of Fuel Delivery Unit & Direction Of Travel

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Tightening Specification