Fuel Tank Overview

Fuel Tank Overview


• Observe the safety precautions when working on the fuel supply. Refer to => [ Safety Precautions ] Fuel Supply.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

Always follow these instructions before and during work.






1 Cap

• Replace if damaged.

2 Bolt

• 1.5 Nm

3 Ground Connection

• Ensure the connection is seated securely.

4 Bolt

• 11 Nm

5 Bracket

• For the electrical Anti-lock Brake System (ABS) speed sensor wire.

6 Fuel Tank

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

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

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

7 Bolt

• 25 Nm

• Always replace.

8 Heat Shield

9 Lock Washer

10 Securing Strap

• Note the installed position.

11 Suspended Mount

• For the exhaust system front muffler. Refer to the following:

Engine code CJAA, see - item 2 - in the => [ Muffler Overview ] Service and Repair.

12 Seal

• Replace if damaged.

• To install, place into the opening in the fuel tank dry.

• Lubricate with fuel only when installing the flange.

13 Fuel Delivery Unit

• Note the installed position of the fuel delivery unit flange. Refer to => [ Installed Position, Fuel Delivery Unit Flange ].

• Removing and installing, refer to => [ Fuel Delivery Unit ] Fuel Delivery Unit.

• With the fuel level sensor.

• Fuel level sensor removing and installing. Refer to => [ Fuel Level Sensor G ] Service and Repair.

• With the transfer fuel pump.

• Checking the transfer fuel pump. Refer to => [ Transfer Fuel Pump G6, Checking ] Transfer Fuel Pump G6, Checking.

14 Lock Ring

• 110 Nm

• Ensure the ring is seated securely.

• Use wrench (T10202) to remove and install.

15 Fuel Supply Line

• Black or with a black mark.

• Clipped to the side of the fuel tank.

• Ensure the line is seated securely.

• To disconnect, press the release button on the connection piece.

• To the fuel filter, see - item 1 - in the => [ Fuel Filter Overview ] Fuel Filter Overview.

16 Fuel Return Line

• Blue or with a blue mark.

• Clipped to the side of the fuel tank.

• Ensure the line is seated securely.

• To disconnect, press the release button on the connection piece.

• From the fuel filter, see - item 3 - in the => [ Fuel Filter Overview ] Fuel Filter Overview.

17 Fuel Filler Door Unit

• With a rubber gasket.

• Removing and installing.

Installed Position, Fuel Delivery Unit Flange





The mark - 3 - on the flange points in the opposite direction of travel.

1. Fuel return line (blue or with a blue mark)

2. Fuel supply line (black or with a black mark)

3. Mark


• The fuel delivery unit flange can only be installed in this position.

• After installing the fuel delivery unit flange, make sure the supply and return lines are still clipped to the fuel tank.