Fuel Tank and Components, Removing and Installing

1 - Cap
2 - Seal
- Replace if damaged
3 - Securing screw
4 - Tank flap unit
- With rubber cup
5 - Vent pipe
- Black
- Check securely seated
- Clipped onto top of fuel tank
6 - Ground connection
- Check securely seated
7 - Vent pipe
- White
- Check securely seated
8 - Gravity valve
- To remove valve unclip upwards out of support
- Check valve for through-flow valve vertical; open, valve tilted 45° : closed
9 - Seal
- Replace if damaged
10 - Change-over valve
- To remove valve unclip sideways out of support
- Before installing remove cap item 1.
- Checking See Fig. 2
11 - Vent pipe
- Black
- Check securely seated
12 - Pressure retention valve
- Checking See Fig. 3
13 - Vent pipe
- Black
- Check securely seated
14 - Fuel tank
- Support with engine and transmission jack V.A.G 1383 A when removing
- Removing and installing
15 - Clamping washer
16 - Heat shield
- For fuel tank
17 - 25 Nm
18 - Lock nut, 2 Nm
19 - Fuel tank cover
20 - Securing strap
- Note differing length
- Installation position: Fixing point (holes) point in direction of travel
21 - Supply pipe
- Black
- Check securely seated
- Press disengaging tabs at connecting piece to pull off fuel filter
- To fuel supply pipe on fuel rail:
22 - Fuel filter
- Installed position: Arrow points in through-flow direction
23 - Screw type clip
24 - Vent pipe
- White
- Check securely seated
- Clipped onto side of fuel tank
25 - Sealing ring
- Replace if damaged
- When installing, insert seal "dry" into fuel tank opening
- only coat to install fuel pump with flange
26 - Fuel delivery unit
- Installed position at fuel tank See Fig. 1
- Removing and installing
- Removing and installing fuel gauge sender
- Checking fuel pump
- Clean strainer if soiled
27 - Union nut, 75 Nm
- Remove and install with spanner 3217
28 - Supply pipe
- Black
- Check securely seated
- Clipped onto side of fuel tank
- To remove from flange and fuel filter press release button on connecting piece
29 - Return pipe
- Blue or with blue marking
- Clipped onto side of fuel tank
- Check securely seated
- To remove from flange press release button on connecting piece
- From fuel return pipe on fuel rail
30 - Connector
- Black, 4-pin
- For fuel gauge sender (G) and fuel pump (G6)
31 - 10 Nm

Fig. 1 Installed position of fuel delivery unit flange







Marking on sender must align with the marking on fuel tank -arrows-.
Blue or blue marked return pipe -1- to connection with identification -R-.
Black supply pipe -2- to connection with identification -V-.


NOTE: After installing fuel delivery unit flange, check that the supply, return and breather pipes are still clipped onto the fuel tank.


Fig. 2 Checking change-over valve







Lever in rest position: Closed
Lever pushed in direction of arrow: Open


NOTE: Before installing change-over valve, unscrew cap from fuel tank.


Fig. 3 Checking vent valve







Pressure retaining valve is open from EVAP canister and from Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- in both flow directions (arrow 1).

From gravity valve side, it is only open in one flow direction (arrow 2).