Fuel Filter: Service and Repair

Fuel Tank and Components, Removing and Installing






1 - Sealing cap
- Secured with strap from MY 2000
2 - Seal
- Replace if damaged
3 - Mounting screw
4 - Tank flap unit
- With rubber cup
5 - Vent pipe
- Black
- Check for tight fit
6 - Ground wire
- Check for tight fit
7 - Vent line
- White
- Check for tight fit
- To Evaporative emissions (EVAP) cannister (item 3)
- Press release tabs on connector to remove from flange
8 - Gravity/overflow - valve
- Removing: pull up out of mount
- Check valve for flow:
- Valve vertical: OPEN
- Valve tilted 45° : CLOSED
9 - O-ring
- Replace if damaged
10 - Change-over valve
- Removing: pull to side, out of mount
- Before installing, remove sealing cap (item 1)
- Checking See Fig. 2
11 - Vent line
- Black
- Check for tight fit
- To Evaporative emissions (EVAP) cannister (item 2)
- Press release tabs on connector to remove from flange
12 - Pressure retention valve
- For fuel reservoir ventilation
- Checking: See Fig. 3
- Press release tabs on connector to remove from flange
13 - Vent line
- Black
- Ensure it is securely seated
- Clipped to fuel tank
14 - Fuel tank
- Support with V.A.G 1383 A engine/transmission jack when removing
- Removing and installing:
15 - Clamping washer
16 - Heat shield
- For fuel tank
17 - 25 Nm (18 ft lb)
18 - Self-locking nut, 2 Nm (18 in. lb)
19 - Fuel tank cover
20 - Mounting straps
- Note differing length
- Installed position: Attaching points (holes) point in direction of travel
21 - Supply line
- Black
- Ensure it is securely seated
- Press release tabs on connector to remove from flange
- To fuel rail:
22 - Fuel filter
- Installed position: arrow points in direction of flow
23 - Screw clip
24 - Vent line
- White
- Ensure it is securely seated
- Clipped onto top of fuel tank
- With EVAP canister purge regulator valve -N80-
25 - Sealing ring
- Replace if damaged
- Lubricate with fuel when installing
26 - Fuel delivery unit
- Note installed position on fuel tank See Fig. 1
- Removing and installing:
- Fuel pump, checking:
- Clean strainer if soiled
27 - Union nut
- Remove and install using 3217 wrench
28 - Return line
- Blue or blue markings
- Clipped to side of fuel tank
- Ensure it is securely seated
- Press release tabs on connector to remove from flange
- From fuel rail:
29 - Connector
- Black, 4 pins
30 - 10 Nm (7 ft lb)

Fig. 1 Fuel delivery unit flange, installed position







NOTE:
- Mark on sensor must align with mark on fuel tank (arrows).
- Blue or blue marked return line -1- to connection with identification -R-.
- Black supply line -2- to connection with identification -V-.
- After installing fuel delivery unit flange, ensure that supply, return and breather lines are still clipped to the fuel tank.

Fig. 2 Change-over valve, checking







- Valve in rest position: CLOSED
- Valve pushed in direction of arrow: OPEN


NOTE: Remove fuel tank cap before installing change-over valve.


Fig. 3 Pressure retention valve, checking







NOTE:
- The pressure retention valve is open in both directions of flow, from the evaporative emissions (EVAP) canister and from EVAP canister purge regulator valve -N80- (arrow 1).
- It is only open in one direction of flow from the junction piece for the gravity/overflow valve (arrow -2).