Fuel Tank: Description and Operation

Fuel Tank and Attachments 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 the engine and transmission jack (V.A.G 1383 A) when removing.

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

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

4 Fuel filter

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

• Always replace flange seal.

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

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 floater.

• 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 Bolt, 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 fuel pump, refer to => [ Fuel Pump, Checking ] Fuel Pump, Checking.

14 Fuel level sensor (G)

• Right side

• Round, spherical floater.

• 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

• With pressure relief valve.

• Always replace flange seal.

• For individual components, refer to => [ Individual Components of the Right Side Flange ]

• 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 the Right Side Flange





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.