Contents: Removal ↓ Installation ↓
On models with petrol engines, the fuel pump together with the fuel level sensor are installed in the fuel tank. On front-wheel drive vehicles with a diesel engine, fuel is taken from the fuel tank by a high-pressure fuel pump and there is no fuel pump in the tank. On all-wheel drive vehicles with a diesel engine, a fuel pump is installed in the fuel tank.
The fuel level sensor design consists of a potentiometer and a float connected to it. When the amount of fuel decreases, the sensor float drops and, by increasing the resistance of the potentiometer, reduces the voltage on the fuel level indicator located on the instrument cluster.
Removal
1. Turn off the ignition and remove the ground cable from the battery.
2. On the right side of the luggage compartment, move the carpet back and unscrew the cover located above the fuel pump/fuel level sensor. To access the cover located above the fuel pump/fuel level sensor on 4WD vehicles, remove the rear seat.
3. Disconnect the electrical connector of the fuel pump/fuel level sensor. Keep in mind that the fuel supply line is under pressure. Before disconnecting the fuel line, relieve the pressure in the fuel system. To do this, loosen the clamp securing the fuel line, then cover the connection with a rag and, being careful, remove the fuel hose from the fitting. Use safety glasses to protect your eyes from fuel.
4. Loosen the clamp and remove the supply and return fuel lines from the fitting of the mounting flange. Close the ends of the lines with suitable plugs.
5. Using the special tool VW-3217, unscrew the flange nut. To unscrew the flange nut on all-wheel drive vehicles, you must use the special tool VW-3087. If you do not have a special tool, unscrew the flange nut using a wooden block and a hammer.
6. Remove the mounting flange and sealing ring from the fuel tank opening.
7. From the inside of the mounting flange, mark and disconnect the electrical connectors and fuel hoses.
8. Carefully disconnect the fuel level sensor and remove it from the fuel tank.
[The original article is posted on the website VWMANUAL]
Gasoline engine
1. Using the special tool VW-3307, release the fuel pump from the retainer by turning it 15° and remove the fuel pump from the tank. The special tool is fixed in the slots of the fuel pump body.
2. Drain the fuel from the fuel pump into a suitable container.
Installation
Alignment of marks when installing the mounting flange on the fuel tank
- 1 - mark on the mounting flange,
- 2 - mark on the fuel tank
1. Install the fuel pump into the fuel tank. Before installation, dip the sealing ring into the fuel.
2. Turn the fuel pump clockwise and fix it in the fuel tank.
3. Secure the fuel level sensor to the fuel tank retainers.
4. Connect the electrical connectors and fuel lines to the back of the mounting flange.
5. Install the mounting flange so that the mark on the flange aligns with the mark on the fuel tank, see Fig. Aligning the marks when installing the mounting flange on the fuel tank.
6. Screw on the flange nut and, using the special tool VW-3217, tighten it to a torque of 60 Nm.
7. Place the supply and return fuel hoses on the fitting of the mounting flange and secure them with clamps. The arrows on the fittings indicate the direction of fuel flow. The return fuel hose is blue.
8. Connect the electrical connector to the mounting flange.
9. Place the cover over the mounting flange and screw it in place.
10. Check that the fuel and ventilation hoses are properly and securely fastened to the fuel tank.
11. Replace the cargo area carpet. On all-wheel drive vehicles, install the rear seat.
12. Connect the ground wire to the battery.
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