Fuel Delivery Unit/Fuel Level Sensor, Removing And Installing: Removing

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.

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 REMOVAL AND INSTALLATION .

-- 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.