Volkswagen Cars 2000-05

Removal & Installation

Print

  1. The sending unit can be reached through the access panel under the rear seat.
  2.  
  3. Disconnect the wiring.
  4.  
  5. Unscrew the locking ring.
  6.  
  7. Lift the sending unit and transfer pump straight out.
  8.  
  9. Before installing the unit, check the condition of the O-ring, replace it if necessary.
  10.  
  11. Installation is the reverse of removal.
  12.  

The fuel sender is located in the fuel tank. A large plastic lock ring must be loosened and removed on all models, before sender is removed. It may be necessary to remove the lock ring using Tool No. 3217.

On Audi A4 models and 1998-00 Passat models the fuel sender is attached to the fuel pump which secured into a mounting bracket the fuel tank. The fuel pump must be rotated approximately 15° counterclockwise to remove. It may be necessary to remove the fuel pump on these models using Tool No. 3307.

  1. The sending unit is accessed by removing bottom trunk trim cover, then removing the access panel. On models with folding down rear seats, the rear seats can be folded down to allow additional access.
  2.  
  3. Disconnect the wiring.
  4.  
  5. Label and disconnect the fuel lines.
  6.  
  7. Unscrew the locking ring turning it counterclockwise using Tool No. 3217 if necessary.
  8.  
  9. On 1990-97 Passat models, lift the sending unit and transfer pump straight out.
  10.  
  11. On A4 and 1998-00 Passat models, turn the fuel pump assembly 15° counterclockwise to release the fuel pump. If necessary use Tool No. 3307 to release, and upon assembly, to install the fuel pump.
  12.  
  13. Before installing the unit, check the condition of the O-ring and if OK, coat lightly with fuel, otherwise replace it if necessary.
  14.  
  15. Installation is in reverse order of removal.
  16.  



Click image to see an enlarged view

Fig. Tool No. 3217 or its equivalent is used to remove and install the fuel pump/sender retaining ring



Click image to see an enlarged view

Fig. Tool No. 3307 is used to remove the fuel pump from the fuel tank on A4 and 1998-00 Passat models



Click image to see an enlarged view

Fig. The access panel to the fuel sender is under the trunk carpet-1.8L Passat model shown



Click image to see an enlarged view

Fig. Remove the Phillips screws to remove the cover and access the fuel sender

 
label.common.footer.alt.autozoneLogo