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 inch lbs.)
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, Refer to Evap (item 5 )
^ 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
11. Vent line
^ Black
^ Check for tight fit
^ To Evaporative emissions (EVAP) cannister, Refer to Evaporative System, Service and Repair, See (item 4 )
^ Press release tabs on connector to remove from flange
12. Pressure retention valve
^ For fuel reservoir ventilation
^ Checking, Refer to 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
^ Removing and installing, Refer to Fuel Tank, Removing and Installing
15. Clamping washer
16. Heat shield
^ For fuel tank
17. 25 Nm (18 ft. lbs.)
18. Self-locking nut, 2 Nm (18 inch lbs.)
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
^ Removing and installing, Refer to Fuel Delivery Valve Assembly, Service and Repair
^ Fuel pump, checking, Refer to fuel pump, Testing and inspection
^ 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 Sender for fuel gauge -G- and fuel pump -G6
31. 10 Nm (7 ft. lbs.)





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 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-.