Reverend wrote:When you do it, make a write up how you did it

i have to do the same to mine. Its in crappy place for sure
OK, I will...
I'm no mechanical genius, but managed to sort this out within a few hours. Firstly, it's worth noting that it is and always has been a diesel, this is worth noting as you may also want to consider buying retaining rings along with the sender unit. (
https://www.brickwerks.co.uk/t3-parts/t3-syncro/engine/turbo-diesel/fuel-system/fuel-sender-retaining-ring-half-t3-syncro-genuine-vw.html) The only reason you might buy these is if the existing threads are really corroded. The main plate sits on the inside, but the threads poke through into the wheelarch area:

My truck has only done 40k, so these were still in pretty good condition. If you can, give the area a good clean with a pressure washer in advance.
Make sure you either run the tank down or syphon your fuel down so that it's below the level of the sender unit. I thought I had, but soon found out I had not after drenching the garage floor with many litres of fuel!
I dabbed penetrating oil on the nuts several times days before the job was done.
Remove the cable from the little plug on the existing unit. Mine just wrecked off as would not come apart, this is quite usual apparently.

I dribbled some penetrating oil in the plug and eased it apart using two pairs of mole grips. The little connection has a tendency to rust, not surprising given the position in the wheelarch.
The nuts are 10mm, which will most likely be fairly corroded. Using a screwdriver, clean up as best as possible. I used a long extension bar and a knuckle to release all but two of the nuts.

There is a plate along the top, no idea what this would have been for? Looks like it was cable routing or something similar. The return pipe has a clip, which I could not quite figure out how to remove, so I wrecked it off with some mole grips. The pipe slid of fairly easily, but I did have to temporarily plug it as diesel kept dribbling out.

I used a short flat bladed screwdriver and prised the send unit away, being careful not to scratch the plastic tank. This is where I wished I had cleaned the area as some dirt fell straight into the tank!

At this stage I decided not to use the retaining rings as the ones there were in perfectly good condition. If it's not broke, don't fix it! Plus I did not want to risk upsetting the internal seal. Clean the seal area and use a new seal. I fixed the replacement unit back on with new nuts and washers.

Gary.
1990 Syncro doka (RHD), 1.6TD.
"ein Leben lebe es"