Fuel Tank and Components Assembly Overview

Fuel Tank and Components Assembly Overview

CAUTION!
During all repair procedures on the fuel tank, be aware of the following:

• Route all the various lines (e.g. for fuel, Evaporative Emission (EVAP) system, or vacuum) and electrical wiring so that the original routing positions are restored.

• Make sure that the ground (-) strap between the fuel filler tube and body is securely fastened, to prevent electrostatic charging.

• Ensure sufficient clearance to all moving or hot components.





1 Fuel filler tube

• With connection for ground strap to body.

• Ensure seated tightly.

2 To EVAP canister

3 Fuel tank

• Support using engine and transmission jack (VAG 1383 A) when removing.

• Removing and installing, refer to --> [ Fuel Tank ] Fuel Tank.

• Draining, refer to --> [ Fuel Tank, Draining ] Fuel Tank, Draining.

4 Fuel filter

• Fuel filter assembly overview, refer to --> [ Fuel Filter Assembly Overview ] Fuel Filter Assembly Overview.

• Always replace flange seal

• Replacing, refer to --> [ Fuel Filter ] Fuel Filter.

5 Locking ring, 110 Nm

• Use wrench (T10202) for removal and installation.

• Ensure seated tightly.

6 Suction jet pump

• Clipped into bottom of tank.

• Removing and installing, refer to --> [ Fuel Level Sensor and Suction Jet Pumps ] Fuel Level Sensor and Suction Jet Pumps.

7 Fuel level sensor 2 (G169)

• Left side

• Flat, rectangular float.

• Clipped into bottom of tank.

• Removing and installing, refer to --> [ Fuel Level Sensor and Suction Jet Pumps ] Fuel Level Sensor and Suction Jet Pumps.

8 Suction jet pump

• Clipped into bottom of tank.

• Removing and installing, refer to --> [ Fuel Level Sensor and Suction Jet Pumps ] Fuel Level Sensor and Suction Jet Pumps.

9 Protective cover

• For bottom of fuel tank.

10 Strap

• Note installation position.

• Ensure seated tightly.

11 20 Nm + 1/4 turn (90°)

12 Protective cover

• For top of fuel tank.

13 Fuel delivery unit

• Removing and installing, refer to --> [ Fuel Delivery Unit and Fuel Level Sensor ] Fuel Delivery Unit and Fuel Level Sensor.

• Checking the fuel pump:

Vehicles with a one piece intake manifold, refer to --> [ Fuel Pump Checking, with One Piece Intake Manifold ] Fuel Pump Checking, with One Piece Intake Manifold.

Vehicles with a two piece intake manifold, refer to --> [ Fuel Pump Checking, with Two Piece Intake Manifold ] Fuel Pump Checking, with Two Piece Intake Manifold.

14 Fuel gauge sender (G)

• Right side.

• Round, spherical float.

• Clipped into bottom of tank.

• Removing and installing, refer to --> [ Fuel Delivery Unit and Fuel Level Sensor ] Fuel Delivery Unit and Fuel Level Sensor.

15 Flange

• Right side.

• Always replace flange seal.

• With pressure relief valve.

• Individual components --> [ Individual Components of Flange, Right Side ]

• Note installation position on fuel tank, refer to --> [ Location of Flange on Fuel Tank ]

16 Vent line

• Ensure seated tightly.

17 Expansion tank

18 Gravity valve

19 To pressure retaining valve

Individual Components of Flange, Right Side





1 Fuel pump connector
2 Ground wire
3 Fuel level sensor (G) connector
4 Pressure relief valve
5 Return pipe
6 Separation point for fuel supply line from fuel filter to flange

Location of Flange on Fuel Tank





- Insert flange with marking - arrow - in direction of travel.