Procedures

Fuel Tank with Attachments Assembly Overview





1 Cap

2 Seal

• Replace if damaged

3 1 Nm

4 Fuel filler door unit

• With rubber gasket

5 Ground connection

• Ensure seated tightly

6 O-ring

• Replace

7 Breather valve

• To remove valve unclip sideways out of support

• Before installing, unscrew cap

• Checking => [ Checking Breather Valve ]

8 6 Nm

9 Protective cover

• Note installation position

10 Vent line

• Ensure seated tightly

11 Lock washer

12 Heat shield

13 Cover for fuel tank

• The rear cover is no longer on the Cabrio

14 20 Nm + 90° (1/4 turn) additional turn

• Replace

15 Securing strap

• Observe varying lengths

16 Fuel tank

• Support using engine/transmission jack (V.A.G 1383 A) when removing

• Removing and installing => [ Fuel Tank ] Removal and Replacement.

17 Seal

• Replace

• To install, place into opening of fuel tank dry

• Only coat inner part with fuel when installing fuel delivery unit.

18 Fuel delivery unit

• Note installation position on fuel tank => [ Installed Location of the Fuel Gauge Sender ]

• Removing and installing => [ Fuel Delivery Unit ] .

• Fuel gauge sender, checking => [ Fuel Level Sensor, Checking ] .

• Fuel pump, checking => [ Tandem Pump, Checking ] Tandem Pump, Checking.

19 Union nut, 75 Nm

• Use ring nut wrench ( 3217) for removal and installation

20 Supply line

• To fuel filter => [ (Item 2) Supply line ]

• Clipped in at fuel tank

• Ensure seated tightly

• Black

• To release the line on the fuel delivery unit, compress the circlip

21 Return line

• Blue

• From the fuel cooler => [ (Item 6) Return line ] Service and Repair or from the fuel filter => [ (Item 1) Return line ]

• Clipped in at fuel tank

• Ensure seated tightly

• To release the line on the fuel delivery unit, compress the circlip

22 Spacer

23 Gravity valve

• To remove valve unclip upward out of support

• Test valve for through-flow

Valve vertical: open Valve angled at 45 degrees: Closed

24 10 Nm

Installed Location of the Fuel Gauge Sender





Marking on flange must align with marking on fuel tank - arrows -.

• After installation, check fuel delivery unit to make sure the fuel supply line - 2 - and the fuel return line - 1 - are still clipped onto fuel tank.

Checking Breather Valve





Lever in rest position: Closed

Lever pushed in direction of arrow: Open

• Before installing bleeder valve, unscrew cap from fuel tank.