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Separating and fitting the fuel level sender G > < Rules for cleanliness

Leon Mk2

Fuel delivery unit: removing and installing
Fuel delivery unit: removing and installing
Special tools and workshop equipment required
   
t  Connection nut wrench -3217-
  W00-0291
t  Torque wrench (40 - 200 Nm) -V.A.G 1332-
Removing
Prerequisite
l  The fuel tank must not be more than 1/2
  Note
If necessary, empty the fuel tank with the fuel extractor -VAS 5190-.
–  Observe the safety precautions before starting work → Chapter .
–  Observe rules for cleanliness → Chapter
–  First check whether a coded radio is fitted. Check the anti-theft code in this case.
–  With the ignition switched off, disconnect battery earth strap.
–  Fold the rear seat base to the front.
–  Remove (by levering) cover from fuel delivery unit.
  WARNING
Fuel supply lines are pressurised! Wear safety gloves and glasses to avoid injury and contact with skin. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
  W00-0428
–  Pull connector -1- and feed line -2- and return line -3- from flange.
  Note
Press in safety ring to release fuel lines.
–  Fit connection nut spanner -3217- on the three rounded ribs on the connection nut and unscrew union nut from flange.
  N20-0604
–  When doing this press connection nut spanner -3217- tightly on the connection nut.
–  Pull fuel delivery unit and seal out of the opening in fuel tank.
  Note
If the delivery unit is to be renewed then drain old delivery unit before disposal.
Fitting
–  Installing the fuel delivery unit is carried out in the reverse order.
  Note
t  When inserting the fuel delivery unit ensure that the fuel gauge sender -G-is not bent.
t  Insert seal for fuel delivery unit dry into opening of fuel tank.
t  Moisten seal with fuel only when installing fuel delivery unit.
  N20-0605
t  Note the fitting position of fuel delivery unit flange: The marks on the fuel tank and the flange must match -arrows-.
t  Do not confuse the fuel supply lines and the return lines.
t  Ensure that wiring connections are securely seated.
t  After installing fuel delivery unit, check that the supply, return and breather pipes are still clipped onto fuel tank.
  N20-0604

Separating and fitting the fuel level sender G > < Rules for cleanliness