By design, the fuel level sensor consists of a potentiometer and an associated float. When the amount of fuel decreases, the sensor float drops and, by increasing the resistance of the potentiometer, lowers the voltage on the fuel gauge located on the instrument cluster.
Removing
1. Switch off ignition and remove a wire of weight from the accumulator.
2. On the right side of the luggage compartment, move the carpet back and unscrew the cover located above the fuel pump/fuel gauge. To access the cover located above the fuel pump/fuel gauge on 4WD vehicles, remove the rear seat.
3. Disconnect the fuel pump/fuel level sensor electrical connector. Be aware that the fuel supply line is under pressure. Depressurize the fuel system before disconnecting the fuel line. To do this, loosen the fuel line clamp, then cover the connection with a rag and, being careful, remove the fuel hose from the fitting. Wear safety goggles to protect your eyes from fuel.
4. Loosen the clamp and remove the supply and return fuel lines from the fittings of the mounting flange. Close the ends of the pipelines with suitable plugs.
5. Using the VW-3217 special tool, unscrew the flange nut. To unscrew the flange nut on four-wheel drive vehicles, you must use the special tool VW-3087. If no special tool is available, unscrew the flange nut using a block of wood and a hammer.
6. Remove the mounting flange and sealing ring from the fuel tank opening.
7. On the inside of the mounting flange, mark and disconnect the electrical connectors and fuel hoses.
8. Using caution, disconnect the fuel level sensor and remove it from the fuel tank.
Gas 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. Fixation of a special tool is carried out in the slots of the fuel pump housing.
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 in the fuel tank. Dip the O-ring in fuel before installing.
2. Turn the fuel pump clockwise and fix it in the fuel tank.
3. Attach the fuel level sensor to the fuel tank clamps.
4. On the reverse side of the mounting flange, connect the electrical connectors and fuel lines.
5. Install the mounting flange so that the mark on the flange is aligned with the mark on the fuel tank, see fig. Alignment of 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. Put 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 fuel return hose is blue.
8. Connect the electrical connector to the mounting flange.
9. Place the cover over the mounting flange and screw it on.
10. Check that the fuel and vent hoses are properly and securely fastened to the fuel tank.
11. Reinstall the luggage compartment carpet. On all-wheel drive vehicles, install the rear seat.
12. Connect ground wire to battery.
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