Fuel Tank and Components, Removing and Installing
Fuel Tank and Components, Removing and Installing
1 - Fuel cap
- Secured with strap from MY 2000
2 - Seal
- Replace if damaged
3 - Bolt
4 - Tank filler flap unit
- With rubber cup
5 - Ground connection
- Check for tight connection
6 - O-ring
- Always replace
7 - Vent valve
- To remove: unclip valve from side of filler neck
- Before installing, remove sealing cap (item -1-)
- Checking, See Fig. 2
8 - 10 Nm (7 ft lb)
9 - Vent line
- Color: black
- Must be securely seated
- Secure with spring clamps
- Clipped to fuel tank
10 - Clamping washer
11 - Heat shield
- For fuel tank
12 - Fuel tank cover
13 - 25 Nm (18 ft lb)
14 - Mounting strap
- Note different lengths
- Note installation position: locator (hole) must point toward driving direction
15 - Fuel tank
- Support with VAG 1383 A engine/transmission jack when removing
- Removing and installing
16 - Sealing ring
- Replace if damaged
- Moisten with fuel when installing
17 - Fuel gauge sensor
- Note installed position on fuel tank, See Fig. 1
18 - Union nut
- Remove and install using 3217 wrench
19 - Supply line
- Black
- Clipped onto fuel tank
- Check for secure fit
- To remove flange: press down on tabs at connection
- To fuel filter (item -2-)
20 - Return line
- From fuel filter, item -2-
- At connection -R-
- Blue or blue markings
- Clipped to fuel tank
- To remove from flange, press down on tabs at connection.
21 - Gravity/overflow - valve
- To remove valve, unclip upward out of support.
- Check valve for flow valve, vertical: open; valve tilted 45° : close
22 - Angled connector
23 - Electrical connector
- Black, 2-pin
Fig. 1 Fuel gauge sensor, installed position
Mark on sensor must align with mark on fuel tank (arrows).
Return line -1-, blue or with blue markings must be attached to connector marked "R".
NOTE: After installing fuel gauge sensor ensure that supply line -2- and return line -1- (marked R) are securely clipped into fuel tank.
Fig. 2 Vent valve, checking
Lever in rest position: closed
Lever pushed in direction of arrow: open
NOTE: Remove fuel tank cap before installing vent valve.