Volkswagen Golf/Jetta 2 manual

Fuel gauge sender unit - removal and refitting
Fuel and exhaust systems - carburettor models / Fuel gauge sender unit - removal and refitting

Warning: The fuel gauge sender unit must always be removed in a well ventilated area.

1 Disconnect the battery negative lead.

2 Lift the luggage compartment floor covering and remove the circular sender unit cover.

3 Disconnect the wiring connector from the top of the unit then detach the fuel supply and return hoses.

4 Undo the retaining nut and lift out the unit, noting its orientation alignment marking. A suitable wrench may be necessary to loosen the securing nut.

5 Renew the sender unit seal.

6 Refit in the reverse order to removal, noting the following:
a) Check that the unit is correctly aligned with the markings in register b) Replace the crimped supply and return line clips with screw type clips c) Check that the wiring connection is secure.

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