Fuel Tank Components, Removing and Installing
Fuel Tank Components, Removing and Installing
1 - Sealing cap
- secured with strap from MY 2000
2 - Seal
- Replace if damaged
3 - Mounting screw
- 1 Nm (9 in. lb)
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
- Press release tabs on connector to remove from flange
8 - Gravity/overflow - valve
- Removing: unclip upward out of support
- Check valve for flow:
- Valve vertical: OPEN
- Valve tilted 45°: CLOSED
9 - O-ring
- Replace if damaged
10 - Change-over valve
- Removing: unclip sideways out of support
- Before installing, remove sealing cap (item 1)
- Checking See Fig. 2
11 - Vent line
- Black
- Check for tight fit
- 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 VAG 1383 A engine/transmission jack when removing
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 supply line on 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 side of fuel tank
- With EVAP canister purge regulator valve N80
25 - Sealing ring
- Replace if damaged
- When installing, insert seal "dry" into fuel tank opening
- Moisten with fuel only when installing flange
26 - Fuel delivery unit
- Note installed position at fuel tank See Fig. 1
- Clean strainer if soiled
27 - Union nut
- Remove and install using 3217 wrench
28 - Supply line
- Black
- Ensure it is securely seated
- Clipped onto side of fuel tank
- To fuel filter
- Press release tabs on connector to remove from flange
29 - Return line
- Blue or blue markings
- Clipped onto side of fuel tank
- Ensure it is securely seated
- Press release tabs on connector to remove from flange
- From fuel return line on fuel rail:
30 - Connector
- Black, 4 pins
- For fuel gauge sender (G) and fuel pump (G6)
31 - 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-.