Fuel Tank: Description and Operation

Fuel Tank and Attachments Overview

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

• Route all the various lines (for example, fuel, Evaporative Emission (EVAP) 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 the connection for the ground strap to the body.

• Ensure the tube is securely seated.

2 to Evaporative Emission (EVAP) Canister

3 Fuel Tank

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

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

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

4 Fuel Filter

• Fuel filter overview, refer to => [ Fuel Filter Overview ] Description and Operation.

• Always replace the flange seal.

• Replacing, refer to => [ Fuel Filter ] Removal and Replacement.

5 Locking Ring

• 110 Nm

• Use wrench (T10202) for removal and installation.

• Ensure the lock ring is securely seated.

6 Suction Jet Pump

• Clipped into the bottom of the 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 the bottom of the 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 the bottom of the tank.

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

9 Protective Cover

• For the bottom of the fuel tank.

10 Securing Strap

• Note the installed position.

• Ensure the is securely seated.

11 Bolt

• 20 Nm + 90° (1/4) additional turn.

12 Protective Cover

• For the top of the 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.

• Fuel pump checking, refer to one of the following:

=> [ Fuel Pump with One Piece Intake Manifold, Checking ] Fuel Pump with One Piece Intake Manifold, Checking.

=> [ Fuel Pump with Two Piece Intake Manifold, Checking ] Fuel Pump with Two Piece Intake Manifold, Checking.

14 Fuel Level Sensor (G)

• Right side

• Round, spherical float

• Clipped into the bottom of the 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 the flange seal.

• With the pressure relief valve.

• Individual components.

• Note the installed position on the fuel tank.

16 Vent Line

• Ensure the line is securely seated.

17 Expansion Tank

18 Gravity Valve

19 to Pressure Retaining Valve

Individual Components of the Right Side Flange





1 Fuel pump connector
2 Ground wire
3 Fuel level sensor 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





- Install the flange with the mark - arrow - in the direction of travel.