FSI Engines Overview
FSI Engines
=> [ In-Tank Wire Routing Assembly Overview ]
=> [ Left Fuel Delivery Unit with Transfer Fuel Pump, Fuel Gauge and Fuel Level Sensor 3 ]
=> [ Right Fuel Delivery Unit with Fuel Pump and Fuel Gauge Assembly Overview ]
In-Tank Wire Routing Assembly Overview
• The illustration shows the ideal routing of the lines on the inside of the fuel tank.
• With exception of the line position. Refer to => [ Installed Location of Fuel Delivery Lines ] , exact routing of the lines is not required, although you must be generally aware of clearance between components and of preventing rattling noises.
• - Arrow - points in direction of travel.
1 Left fuel delivery unit with Transfer Fuel Pump (FP) (G6)
2 Fuel delivery line
• From left suction jet pump to right fuel delivery unit
3 Suction jet pipe
• From right fuel pump to left suction jet pump
4 Left suction jet pump
5 Suction jet pipe
• For the left fuel delivery unit
6 Expansion tank
• With suction jet pump to pump fuel from the reservoir
7 Check valve
• For fuel filler line
8 First-time filling fuel line
• To right fuel delivery unit
• Serves to supply a small amount of fuel directly to the delivery unit during first-time filling
9 Suction jet pipe
• For the right fuel delivery unit
10 Right suction jet pump
11 Suction jet pipe
• From the left fuel pump to right suction jet pump
12 Fuel delivery line
• From right suction jet pump to left fuel delivery unit
13 Right fuel delivery unit with Fuel Pump (FP) (G23)
14 Fuel supply line
• From the left and right fuel pumps to the locking flange
15 Vent line
• To vent connection at top on fuel filler neck
16 Vent line
• To the EVAP canister in the spare wheel well on vehicle floor
17 Fuel return line
• From the locking flange to the right fuel delivery unit
• Inserted loosely into the right fuel delivery unit
18 Fuel filling line
• From filler tube to check valve in fuel tank
19 Suction jet pipe
• To suction jet pump in reservoir
20 Overflow line
• Between the fuel delivery units
Installed Location of Fuel Delivery Lines
• The delivery lines - 1 - and - 3 - must be routed under the fuel filler line - 2 - in the area of the left fuel tank opening.
Left Fuel Delivery Unit with Transfer Fuel Pump, Fuel Gauge and Fuel Level Sensor 3
1 Support
• For fuel delivery unit
2 Fuel Level Sensor (G)
• Black
• Clipped into mount - 1 -
• Resistance values, checking, refer to => [ Fuel Level Sensor, Checking, Left Lever-Type Sensor ] Fuel Level Sensor, Checking, Left Lever-Type Sensor
• Removing and installing, refer to => [ Fuel Level Sensor 1, Left Lever-Type Sensor ] Fuel Level Sensor 1, Left Lever-Type Sensor
3 Left fuel delivery unit
• With Transfer Fuel Pump (FP) (G6)
• Clipped into mount - item 1 -
• Different versions, allocation
• Fuel pump electrical, checking, refer to => [ Transfer Fuel Pump, Left, Checking Electrical ] MPI Engines
• Removing and installing, refer to => [ Left Fuel Delivery Unit with Transfer Fuel Pump ] MPI Engines
• After installing, fuel vehicle with at least 5 liters of fuel
4 Fuel delivery line
• From suction jet pump, right side
• Clipped onto fuel delivery unit - 3 -
5 Suction jet pipe
• For the left fuel delivery unit
6 Suction jet pipe
• To the right suction jet pump
7 Fuel supply line
• The connection is located on right side of fuel tank
• To disconnect, press release button on connection piece
8 Locking ring
• Use Wrench (T10202) for removal and installation
• Tighten to: 120 Nm.
9 Left locking flange
• Installed location, refer to => [ Installed Location of Left Locking Flange ]
10 Seal
• Replace
• Install dry
11 Overflow line
• To right fuel delivery unit
12 Fuel Level Sensor 3 (G237)
• Gray
• Clipped onto fuel delivery unit - 3 -
• Resistance values, checking, refer to => [ Fuel Level Sensor 3, Checking, Left Tubular Sensor ] Fuel Level Sensor 3, Checking, Left Tubular Sensor
• Removing and installing, refer to => [ Fuel Level Sensor 3, Left Tubular Sensor ] Fuel Level Sensor 3, Left Tubular Sensor
Installed Location of Left Locking Flange
- Install the new locking flange seal dry.
- Insert locking flange in fuel tank, note installation position:
• The tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.
Right Fuel Delivery Unit with Fuel Pump and Fuel Gauge Assembly Overview
1 Support
• For fuel delivery unit
2 Fuel Level Sensor 2 (G169)
• Yellow
• Clipped into mount - 1 -
• Resistance values, checking, refer to => [ Fuel Level Sensor 2, Checking, Right Lever Sensor ] Fuel Level Sensor 2, Checking, Right Lever Sensor
• Removing and installing, refer to => [ Fuel Level Sensor 2, Right Lever Sensor ] Fuel Level Sensor 2, Right Lever Sensor
3 Fuel Level Sensor 4 (G393)
• White
• Clipped onto fuel delivery unit - 16 -
• Resistance values, checking, refer to => [ Fuel Level Sensor 4, Checking, Right Tubular Sensor ] Fuel Level Sensor 4, Checking, Right Tubular Sensor
• Removing and installing, refer to => [ Fuel Level Sensor 4, Right Tubular Sensor ] Fuel Level Sensor 4, Right Tubular Sensor
4 Fuel supply line
• To fuel filter
• Mark before removing
• To disconnect, press release button on connection piece
• Do not kink
• Clipped in on fuel tank
5 Fuel return line
• From fuel rail
• Mark before removing
• To disconnect, press release button on connection piece
• Do not kink
• Clipped in on fuel tank
6 Locking ring
• Use Wrench (T10202) for removal and installation
• Tighten to: 120 Nm.
7 Seal
• Replace
• Install dry
8 Right locking flange
• Installed location, refer to => [ Installed Location of Right Locking Flange ]
9 Fuel return line
• From the locking flange to the right fuel delivery unit
• Inserted loosely into the right fuel delivery unit
10 Fuel supply line
• From the fuel delivery units to the locking flange
11 Overflow line
• Between the fuel delivery units
12 Suction jet pipe
• For suction jet pump
• To disconnect, press release button on connection piece
13 Fuel delivery line
• From suction jet pump, left side
• Clipped onto fuel delivery unit - 16 -
14 Suction jet pipe
• For the right fuel delivery unit
15 Fuel filler tube
• Fuel filler tube
• Clipped onto fuel delivery unit - 16 -
16 Right fuel delivery unit
• With Fuel Pump (FP) (G23)
• Clipped into mount - 1 -
• Different versions, allocation
• Fuel pump electrical, checking, refer to => [ Fuel Pump, Right, Checking Electrical ] MPI Engines
• Removing and installing, refer to => [ Right Fuel Delivery Unit with Fuel Pump ] FSI Engines
• After installing, fuel vehicle with at least 5 liters of fuel
Installed Location of Right Locking Flange
- Install the new locking flange seal dry.
- Insert locking flange in fuel tank, note installation position:
• The tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.