Fuel System Components
Fuel System Components
• Fuel hoses at engine may only be secured with spring-type clamps appropriate for the model type.
• Spring Type Clip Pliers (VAS 6499) or Hose Clip Pliers (VAS 6362) are recommended for installing spring clamps.
• If fuel delivery unit was replaced, adapt Engine Control Module to Fuel Pump (FP) "Guided Functions".
=> [ Fuel Delivery Unit ]
=> [ Fuel Level Sensor ]
=> [ Fuel Tank ]
Fuel Delivery Unit
Special tools, testers and auxiliary items required
• Wrench (T10202)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
Removing
CAUTION!
Requirement:
• The fuel tank may be a maximum of 3/4 full. This ensures the fuel level is below the fuel delivery unit flange.
• When replacing the fuel delivery unit, check the fuel tank for visible contamination and clean if necessary.
• Drain the fuel tank if necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.
• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.
- Remove the rear seat bench.
- Remove the cover - 1 - with the fuel pump control module (J538) - 2 - from the fuel delivery unit.
CAUTION!
The fuel system is under pressure!
• Wear protective goggles and protective clothing to prevent injuries and contact with skin.
• Before disconnecting the connections, place a cloth around the connection point. Then release pressure by carefully disconnecting the connection.
- Disconnect the 5 pin connector - A - and disconnect the fuel line - B - from flange.
• Press in the securing ring to disengage the fuel line.
- Remove the locking ring using (T10202).
- Lift the flange up.
- Disconnect the coupling - A - and remove the suction jet pump - B -. To do so, press the tabs - arrows - together.
• Press in the circlip to disengage the coupling - A -.
- Pull the seal and fuel delivery unit out of the fuel tank opening.
• If the delivery unit is to be replaced then drain the old delivery unit before disposal.
• Follow the disposal regulations.
Installing
CAUTION!
Do not bend the fuel level sensor (G) float arm when installing.
- Insert the fuel delivery unit without the suction jet pump into the fuel tank.
- Install the suction jet pump - B - and connect the coupling - A -. Pull on the coupling to make sure it is securely fastened.
- Install the flange onto the delivery unit.
• Make sure the hoses are fastened correctly.
- Install the seal - A - over the flange and insert it into the fuel tank opening.
- Lubricate the seal lightly with fuel and press the flange into the fuel tank.
- Installed position: the mark - A - points in the opposite direction of travel.
- Tighten the locking ring using (T10202). Tightening specification: 110 Nm.
Further installation is performed in reverse order. When doing this note the following:
• - Arrow - on the cover must point in direction of travel.
• Route the fuel lines free of kinks.
• Pull on the line connections to make sure they are securely fastened.
• If fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump. Refer to "Guided Functions" in he vehicle diagnostic tester.
Fuel Level Sensor
Removing
- Remove the fuel delivery unit. Refer to => [ Fuel Delivery Unit ].
- Pull the fuel level sensor (G) slightly to the side and simultaneously upward.
- If the sensor cannot be released this way, press the retaining tabs - arrows - to the side slightly.
- Note the colors of the wires for installing later.
- Disengage electrical connectors - 1 through 3 - and disconnect them. Bend the retaining hooks on the connector back.
Installing
- Connect the connectors - 1 through 3 -. Note the color coding.
- Pull on the connectors to make sure they are securely fastened.
- Install the fuel level sensor into the guides on the fuel delivery unit and push down until it engages.
- Install the fuel delivery unit. Refer to => [ Fuel Delivery Unit ].
Fuel Tank
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Engine/Transmission Jack (V.A.G 1383 A)
Removing
• The rear subframe must be lowered to remove fuel tank.
- Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.
Drain the fuel tank if necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
- Remove the rear seat bench.
- Remove the cover - 1 - with the fuel pump control module (J538) - 2 - from the fuel delivery unit.
- Disconnect the 5 pin connector from the flange.
- Remove the right rear wheel.
- Remove the right rear wheel housing liner.
- Disconnect the vent lines and vacuum line - arrows - from the Evaporative Emission (EVAP) canister.
- Unclip the electrical wire from the fuel filler tube.
- Remove the fuel door unit.
- Remove the fuel filler tube to body bolts - arrows -.
CAUTION!
The fuel system is under pressure!
• Wear protective goggles and protective clothing to prevent injuries and contact with skin.
• Before disconnecting the connection, place a cloth around the connection point. Then release pressure by carefully disconnecting the connection.
• Press in the securing ring to disengage the fuel line.
- Disconnect the ventilation line (white), vacuum line (green) and fuel line (black) at the connection point.
- Support the rear subframe using the (V.A.G 1383 A).
- Loosen the bolts - arrows - and lower the rear subframe.
- Remove the tensioning strap bolts - arrows -. Support the fuel tank using (V.A.G 1383 A) beforehand.
- Slowly lower the fuel tank.
• The fuel filler tube must be removed between the chassis and rear subframe. To do so, lift the fuel tank with help from a second mechanic, down from the (V.A.G 1383 A).
Installing
- With help from a second technician, guide the fuel filler tube between the rear subframe and chassis. Then place the fuel tank onto the (V.A.G 1383 A).
- Lift the fuel tank slowly up to the installed position and secure it.
• To install the fuel tank straps, only bolts with loose washers may be used. If other bolts are used, the straps could twist when the bolts are tightened.
- Secure the rear subframe to the body.
Further installation is performed in reverse order. When doing this note the following:
• Make sure the vent and fuel lines are not kinked.
• Pull on the line connections to make sure they are securely fastened.
• Check the Ground (GND) connection for the fuel tank/chassis at the filler tube.
• If the fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to fuel pump. Refer to "Guided Functions" in the vehicle diagnostic tester.
Tightening Specifications
1 replace