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Removing and installing fuel gauge sender > < Emptying fuel tank if it is less than 3/4 full

Golf Mk5

Removing and installing fuel delivery unit
Removing and installing fuel delivery unit
Special tools and workshop equipment required
   
t  Special wrench -T10202-
  W00-1334
t  Torque wrench -V.A.G 1332-
Removing
Observe safety precautions → Chapter.
Observe rules for cleanliness → Chapter.
–  First check whether a coded radio is fitted. If so, obtain anti-theft coding.
–  Disconnect earth strap from battery with ignition switched off → Electrical system; Rep. gr.27.
–  Fold rear seats forwards.
–  Detach carpet under seats and fold it back. → General body repairs, interior; Rep. gr.70
  W00-0428
–  Remove cover from fuel delivery unit.
–  Pull 5-pin connector and fuel lines off flange.
  Note
Press buttons on hose couplings to do this.
  WARNING
t  The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
t  The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!
t  Wear eye and hand protection when performing any type of repair work on the fuel system!
  N20-0687
–  Remove union nut with wrench -T10202-.
–  Pull fuel delivery unit and seal out of opening in fuel tank.
  Note
If delivery unit is to be renewed, drain old delivery unit before disposal.
Installing
–  Installation of fuel delivery unit is carried out in reverse order.
  Note
t  Do not bend fuel gauge sender when installing.
t  Insert seal for flange or fuel delivery unit dry into opening of fuel tank.
t  Moisten seal with fuel only when installing flange or fuel delivery unit.
t  Ensure that fuel hose connections are tight.
t  After installing fuel delivery unit, check that supply, return and breather lines are still clipped onto fuel tank.
  N20-0638
t  Note installation position of fuel delivery unit flange: mark on flange must align with mark -arrows- on fuel tank.
  N20-0704

Removing and installing fuel gauge sender > < Emptying fuel tank if it is less than 3/4 full