Fuel Delivery and Air Induction: Service and Repair

NOTE:
- Secure all hose connections using same type of clips as originally installed.
- VAG 1921 Pliers are recommended for installing spring clips.
- Always replace seals and gaskets.





1 - Sender for fuel gauge - G -
- Checking resistance values, refer to "Sender For Fuel Gauge - G -, Checking (All wheel drive )" under Instrument Panel, Gauges and Warning Indicators/Fuel Gauge Sender Testing and Inspection
- Removing and installing.
2 - Fuel pump
- Removing and installing.
- Check Fuel Pump (FP) electrically. Refer to "Fuel Pump, Electrical Testing" Testing and Inspection
- Checking residual pressure.
3 - Seal
- Always replace
- To install, place into opening of fuel tank when dry
4 - Return line
- Blue
- From fuel rail
- Attaches to connection with "R" marking at connector flange
- To remove connector flange, press release button on connecting piece
5 - Supply line
- Black
- To fuel filter
- Attaches to connection with "V" marking at connector flange
- To remove from connector flange or from filter, press release button on connecting piece.
6 - 4 - pin harness connector
- For Fuel Pump (FP), sender for fuel gauge - G - and sender 2 for fuel gauge - G169 -
7 - Union nut - 80 Nm
- Use ring nut spanner 3217 to remove and install
8 - 2 - pin harness connector
- For sender 2 for fuel gauge - G169 -
9 - Union nut - 80 Nm
- Use ring nut spanner 3217 to remove and install
10 - Seal
- Always replace
- To install, place into opening of fuel tank when dry.
11 - Secondary fuel pump
- With connecting flange
- With wiring
- Removing and installing.
12 - Sender 2 for fuel gauge - G169 -
- Checking.
- Removing and installing.
13 - Hose coupling
- For fuel hose to secondary fuel pump
- To disconnect, press release button
14 - Retaining strap
- For fuel hose from secondary fuel pump
- Engage in fuel pump and press in locking mechanism