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

Leon Mk2

Removing and installing fuel delivery unit
Removing and installing fuel delivery unit
Special tools and workshop equipment required
   
t  Union nut tool -3217-
  W00-0291
t  Torque wrench (40...200 Nm) -V.A.G 1332-
Removing
–  Note safety precautions before beginning work → Chapter.
Observe rules for cleanliness → Chapter.
–  First check whether a coded radio is fitted. If so, obtain anti-theft coding.
–  With the ignition switched off, disconnect battery earth strap.
–  The fuel tank must not be more than 3/4 full when removing the fuel delivery unit. Empty fuel tank if necessary → Chapter.
–  Remove both centre seats → Rep. Gr.72.
–  Fold back floor carpet.
–  Remove cover from fuel delivery unit.
  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!
  W00-0428
–  Pull return line -1-, supply line -2-, fuel line for additional heater (if fitted) -3- and 4-pin connector -4- off fuel delivery unit flange.
  Note
Press in securing ring to release fuel lines.
  N20-10277
–  Loosen union nut using union nut tool -3217-.
–  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  When inserting fuel delivery unit, ensure that fuel gauge sender is not bent.
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  Fuel lines are to be installed free of kinks.
t  Do not interchange supply and return lines (return line green, supply line black).
t  Ensure fuel hoses are tight.
t  Connections for fuel lines must engage audibly when joined.
t  After installing fuel delivery unit, check that supply and return lines are still clipped onto fuel tank.
t  Observe fitting position of fuel delivery unit flange → Fig..
  A20-0106

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