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

Installation of the fuel delivery unit is performed in the reverse order of removal. Note the following:

-- Replace the seal

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

-- Coat the inside of the seal with fuel.

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

-- Install the suction jet pump intake line and lock it into place. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Press the sealing flange downward against the spring force and move the sealing flange into the installation position.

Sealing Flange Installation Position: 

Fig 1: Fuel Delivery Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Tighten the locking ring using the : T10202  .

Fig 2: Identifying Locking Ring And Wrench T10202

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the fuel lines -1 and 2-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 3: Fuel Lines At Flange

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the connector -arrow-.

Fig 4: Fuel Pump Control Module Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull on the connectors and connector couplings to check if them for secure fit.

Further installation is performed in reverse order of removal.