Fuel Pump: Service and Repair: Overview
Engine Code BPS (Plastic Fuel Tank)
Fuel Tank and Attachments Assembly Overview
1 Cap
2 Seal
• Replace if damaged.
3 Bolt
4 Fuel Filler Door Unit
• With rubber gasket.
5 Bolt, 10 Nm
6 Vent Line
• Ensure the line is securely seated.
7 Switch Over Valve
• To remove the valve, unclip sideways out of the support.
• Before installing, remove the cap - item 1 -.
• Checking, refer to => [ Switch Over Valve Checking ].
8 O-ring
• Replace if damaged.
9 to Evaporative Emission (EVAP) Canister
10 from EVAP Canister
11 Wiring Router
• In the longitudinal member.
12 Vent Line
• Ensure the line is securely seated.
• Secure with spring type clips.
13 Bolt, 10 Nm
14 Protective Plate
15 Fuel Tank
• Support using the engine and transmission jack (VAG 1383A) when removing.
• Removal and installation, refer to => [ Fuel Tank ] Removal and Replacement.
16 Heat Shield
• For the fuel tank.
17 Lock Washer
18 Cover for Fuel Tank
19 Bolt, 20 Nm + 90° (1/4) additional turn
• Replace
20 Securing Strap
• Observe the varying lengths.
• Installed position: Locating point (hole) points in the driving direction.
21 Fuel Filter
• Installed position: Arrow points in direction of flow.
• Assembly overview, refer to => [ Fuel Filter Assembly Overview ].
• Removal and installation, refer to => [ Fuel Filter ] Removal and Replacement.
22 Supply Line
• Black
• Ensure the line is securely seated.
• To disconnect from the fuel filter, press in the securing ring on the connecting piece.
• To the fuel rail.
23 Vent Line
• White
• Clipped in at the top of the fuel tank.
• Ensure the line is securely seated.
• To the EVAP canister purge regulator valve (N80 ).
24 Seal
• Replace
• To install, place into the opening of the fuel tank dry.
• Only coat the inner part with fuel when installing the fuel delivery unit.
25 Fuel Delivery Unit
• Note the installed position in the fuel tank, refer to => [ Fuel Delivery Unit Installed Position ].
• Removal and installation, refer to => [ Fuel Delivery Unit ] Removal and Replacement.
• Fuel level sensor removal and installation, refer to => [ Fuel Level Sensor ] Removal and Replacement.
• Fuel pump checking, refer to => [ Fuel Pump Checking, Engine Code BPS (Plastic Fuel Tank) ] Fuel Pump Checking, Engine Code BPS (Plastic Fuel Tank).
• Clean the strainer if contaminated.
26 Locking Ring, 110 Nm
• Ensure the ring is securely seated.
• Use wrench (T10202) for removal and installation.
27 Supply Line
• Black
• To the fuel filter.
• Ensure the line is securely seated.
• To disconnect from the flange and fuel filter, press in the securing ring on the connecting piece.
• Clipped to the side of the fuel tank.
28 Return Line
• Blue
• To the fuel filter.
• Ensure the line is securely seated.
• To disconnect from the flange and fuel filter, press in the securing ring on the connecting piece.
• Clipped to the side of the fuel tank.
29 Gravity Valve
• To remove the valve, unclip upward out of the support.
• Checking valve for throughput:
Valve vertical: Open
Valve angled at 45°: Closed
30 Pressure Retention Valve
• For fuel tank ventilation.
• Checking, refer to => [ Pressure Retention Valve Checking ].
31 Ground Connection
• Ensure the connection is securely seated.
Fuel Delivery Unit Installed Position
The tab - 4 - on the fuel delivery unit must lie between tabs - 3 and 5 -.
• - Arrow - points in direction of travel.
• Fuel delivery unit can only be installed in this position.
Switch Over Valve Checking
Pin in rest position: Closed
Pin pressed in the - direction of the arrow -: Open
• Before installing change over valve, remove the cover from the fuel tank.
Pressure Retention Valve Checking
The pressure retaining valve is opened in both flow directions - arrow 1 - on the gravity valve side.
It is only open in one flow direction - arrow 2 - from the T-piece of the EVAP canister/solenoid valve 1.