Fuel Filter: Service and Repair

1 - Cap
- Secured with strap from MY 2000
2 - Sealing ring
- Replace if damaged
3 - Retaining screw
4 - Fuel filler door module
- With rubber seal
5 - Vent line
- Black
- Make sure tight fit
6 - Ground connection
- Make sure tight fit
7 - Vent line
- White
- Make sure tight fit
- To activated carbon canister, item -3-
- Press release tabs on connecting piece to remove from flange
8 - Gravity/overflow - valve
- Remove by clipping valve upwards out of its fitting
Checking valve passage
- Valve vertical. open
- Valve tipped 45° : closed
9 - O-Ring
- Always replace
10 - Switch-over valve
- Remove by clipping valve sideways out of its fitting
- Remove cap -1- before installing
- Checking See Fig. 2
11 - Vent line
- Black
- Make sure tight fit
- To activated carbon canister, item -2-
- Press release buttons on connecting piece to remove from flange
12 - Pressure valve
- For fuel tank ventilation
- Check See Fig. 3
- Clip onto fuel tank
13 - Vent line
- Black
- Make sure tight fit
- Fasten with spring band clips
- Clip onto fuel tank
14 - Fuel tank
- Hold with VAG 1383 A engine/transmission hoist when removing
- Removing and installing
15 - Clamping disk
16 - Heat shield
- For fuel tank
17 - 25 Nm
18 - Clamping nut, 2 Nm
19 - Fuel tank cover
20 - Tightening strap
- Watch for different lengths
- Install position: the fastening (boring) points in the direction of travel
21 - Feed line
- Black
- Make sure tight fit
- Press release tabs on connecting piece to remove from flange
- To fuel rail:
22 - Fuel filter
- Install position: arrow shows the direction of flow
23 - Screw clamp
24 - Vent line
- White
- Make sure tight fit
- Clip onto fuel tank
- To solenoid valve 1 for charcoal canister -N80-
25 - Sealing ring
- Replace if damaged
- Moisten with fuel for assembly
26 - Fuel delivery module
- Note install position on the fuel tank See Fig. 1
- Removing and installing
- Checking fuel pump
- Clean strainer if contaminated
27 - Union nut
- Removing and installing with wrench 3217
28 - Feed line
- Black
- Clip onto fuel tank
- Press release tabs on connecting piece to remove from flange
29 - Return line
- Blue or blue marking
- Clip onto fuel tank
- Make sure tight fit
- Press release tabs on connecting piece to remove from flange
- From fuel rail:
30 - Connector
- Black, 4-way
31 - 10 Nm

Fig. 1 Fitting position of the fuel delivery module flange







Markings on the sensor must agree with those on the fuel tank -arrows-.
Return line -1- with blue or with blue markings at port labeled -R-.
Black feed line -2- at port labeled -V-.


NOTE: After the flange of the fuel delivery module is installed, check that the feed, return, and vent lines are still clipped onto the fuel tank.


Fig. 2 Switch valve, check







Lever in rest position: closed
Lever pressed in direction of arrow: open


NOTE: Remove the fuel tank cover before installing the switch valve.


Fig. 3 Checking the pressure valve







- Check the valve flow:

A) Orifices 1 - 1:
- Flow in both directions, port 2 closed

B) Orifices 2 - 1:
- Flow in both directions, port 3 closed

C) Orifices 1 - 2:
- Flow in one direction, port 3 closed

The valve will close when there is vacuum at opening 1.