Fuel System Components
Fuel System Components
• Fuel hoses at the engine may only be secured with spring-type clamps appropriate for the model type.
• Hose clip pliers (VAS 6362) or hose clip pliers (V.A.G 1921) are recommended for installing spring clamps.
=> [ Fuel Delivery Unit ]
=> [ Fuel Level Sensor (G) ]
=> [ Suction Jet Pump, Fuel Filter and Pressure Relief Valve ]
=> [ Fuel Level Sensor 2 (G169) ]
=> [ Fuel Pump Control Module (J538) ]
=> [ Fuel Tank ]
Fuel Delivery Unit
Special tools, testers and auxiliary items required
• Assembly Tool (T10118)
• Wrench (T10202)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Fuel Extracting Device (VAS 5190)
Removing
Requirement:
• The fuel tank may be a maximum of 1/2 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 using the fuel extracting device (VAS 5190) if necessary.
• 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 from the fuel delivery unit.
- First, pull on the 5 pin connector - 1 - without pressing the release to make sure it is connected securely. If the connector was not connected correctly, it could cause a fault.
- Disconnect the connector - 1 -.
- Check the contacts on the connector and the fuel delivery unit for damage.
- Disengage the connector - arrow - on the fuel pump control module (J538) using the assembly tool (T10118) and remove it.
Fuel lines are under pressure.
Danger of personal injury to eyes and skin.
Wear protective goggles and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Open the connection carefully and release the pressure.
- Disconnect the supply line - 2 - and wipe up the leaking fuel with a cloth.
- Remove the locking ring using the wrench (T10202).
- Lift the fuel delivery unit slightly and remove the seal from the fuel tank opening.
- Disconnect the fuel hoses on the delivery unit - arrows - and remove the delivery unit out of the fuel tank.
• If the delivery unit is to be replaced then drain the old delivery unit before disposal.
Installing
- Connect the fuel hoses - arrows -. Make sure the fuel hoses engage audibly and pull on them to make sure they are securely fastened.
- Installation of the fuel delivery unit is the reverse of removal.
• The fuel hoses are assigned to the connections.
• Pull on the connectors to make sure they are securely fastened.
• Do not bend the fuel level sensor (G) float arm when installing the fuel delivery unit.
• Install the seal for the fuel delivery unit into the fuel tank opening dry.
• Lubricate the seal with fuel only when installing the fuel delivery unit.
• Note the fuel pump flange installed position: The tab - 1 - must face in the direction of travel. The fuel delivery unit flange can only be installed in this position.
Fuel Level Sensor (G)
- Remove the fuel delivery unit. Refer to => [ Fuel Delivery Unit ].
Special tools, testers and auxiliary items required
• Welding Wire (2 mm material strength)
- Bend an 80 mm long welding wire as shown.
Dimension - a -: 10 mm
Dimension - b -: 70 mm
Removing
- Disengage and remove the wire terminals from the fuel level sensor.
- Press the welding wire - 1 - in the - direction of the arrow - into the opening under the sensor.
- At the same time, push the fuel level sensor - 2 - in the - direction of the arrow - out of the guides.
Installing
- Insert the fuel level sensor in the guides on the fuel delivery unit and push down until it engages.
- Connect the connector and check for secure locking.
- Install the fuel delivery unit. Refer to => [ Fuel Delivery Unit ].
Suction Jet Pump, Fuel Filter and Pressure Relief Valve
Special tools, testers and auxiliary items required
• Wrench (T10202)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• On All Wheel Drive (AWD) vehicles, the fuel must be pumped out of the fuel level sensor 2 (G169) area and to the fuel delivery unit due to the shape of the fuel tank. A suction jet pump pumps the fuel from the left chamber to the right chamber in the fuel tank.
• The fuel delivery unit must be removed first in order to remove the suction jet pump.
• The left flange consists of the suction jet pump, fuel filter, pressure relief valve and fuel level sensor 2. Only the fuel level sensor 2 can be replaced separately.
• Only check the fuel level sensor 2 if the engine shuts off due to low fuel but the fuel gauge indicates the tank is still 1/4 full.
Removing
- Remove the rear seat bench.
- Remove the fuel delivery unit. Refer to => [ Fuel Delivery Unit ].
- Remove the left cover (when viewed from the direction of travel) from the fuel level sensor 2.
- First, pull on the connector without pressing the retainer to make sure it is connected securely. If the connector was not connected correctly, it could cause a fault.
- Disconnect the connector - 1 - from the left flange.
- Remove the locking ring using the wrench (T10202).
- Lift the flange slightly and remove the seal from the fuel tank opening.
- Remove the flange from the fuel tank together with the fuel level sensor 2.
- Check the fuel lines for kinks and damage.
- Check the suction jet pump and the fuel tank for any contamination.
Installing
Do not bend the fuel level sensor 2 float arm when installing.
- Insert the flange in the fuel tank together with the fuel level sensor 2. The tab on the flange faces in the direction of travel.
- Route the fuel lines in the right chamber of the fuel tank so they are not kinked.
- Insert a new, dry seal into the fuel tank opening. Only lubricate the inner side of the seal that comes into contact with the flange with fuel.
- Note the fuel level sensor 2 installed position. Refer to => [ Installed Position of the Fuel Delivery Unit Flange and Fuel Level Sensor 2 ] Fuel Tank and Attachments Overview.
- Make sure the seal is in the correct location.
- Tighten the locking ring using the wrench (T10202). Tightening specification: 110 Nm.
- Connect the connector - 1 - and pull on it to make sure it is connected securely.
- Install the fuel delivery unit. Refer to => [ Fuel Delivery Unit ].
The rest of the installation follows the reverse of the removal procedures.
Fuel Level Sensor 2 (G169)
Special tools, testers and auxiliary items required
• Welding wire (2 mm material strength)
- Bend an 80 mm long welding wire as shown.
Dimension - a -: 10 mm
Dimension - b -: 70 mm
Removing
- Remove the suction jet pump. Refer to => [ Suction Jet Pump, Fuel Filter and Pressure Relief Valve ]
- Disconnect the connectors for the fuel level sensor 2 - 2 -.
- Press the welding wire - 1 - in the - direction of the arrow - into the opening under the sensor.
- At the same time, slide the fuel level sensor 2 - 2 - in the - direction of the arrow - from the guides.
Installing
- Install the fuel level sensor 2 into the guides and push it down until it latches.
- Connect connector and check for secure locking.
- Install the suction jet pump. Refer to => [ Suction Jet Pump, Fuel Filter and Pressure Relief Valve ].
Fuel Pump Control Module (J538)
• The fuel pump control module is located on the fuel tank.
Special tools, testers and auxiliary items required
• Flat Blade Screwdriver (blade length 120 mm)
Installed location of the fuel pump control module
1 Fuel pump control module bracket
2 Fuel pump control module
3 Connector
Removing
- Remove the cover that is on the right side of the fuel delivery unit when viewed in the direction of travel.
- First, pull on the 5 pin connector - 1 - without pressing the release to make sure it is connected securely. If the connector was not connected correctly, it could cause a fault.
- Disconnect the connector - 1 -.
- Check the contacts on the connector and the fuel delivery unit for damage.
- Push the screwdriver - 2 - into the opening in the bracket - 1 - directly above the connector.
- Swivel the screwdriver in the - direction of the arrow -.
- Press the screwdriver downward in the - direction of the arrow - and pull the control module out of the bracket at the same time.
- First, pull on the connector without pressing the retainer to make sure it connected securely. If the connector was not connected correctly, it could cause a fault.
- Disconnect the connector from the control module.
Installing
- Connect the connector - 3 - to the control module - 2 - and pull on it to make sure it is connected securely.
- Install the control module - 2 - into the bracket - 1 - until it latches.
Further installation is performed in reverse order of removal.
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
- Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.
- Does the vehicle have a coded radio? If so, obtain the anti-theft code from the customer.
- Turn off the ignition and disconnect the ground cable from the battery.
- Remove the bolt for the fuel flap and remove the fuel flap unit.
- Drain the fuel tank and clean the fuel filler tube and surrounding area.
- Remove the rear seat bench.
- Remove the cover from the fuel delivery unit.
- Disconnect the connector - 1 - and the fuel line - 2 - from the right flange when viewed in the direction of travel.
- Disengage the connector - arrow - from the fuel pump control module (J538) using the assembly tool (T10118) and remove it.
- Disconnect the connector - 1 - from the left flange when viewed in the direction of travel.
- Remove the rear exhaust system with the center and rear mufflers.
- First, remove bolt - 1 -, then bolts - 2 and 3 - and then remove the pendulum support.
- Remove the driveshaft. Refer to => Rear Final Drives 01Z, 0BS and 0AY.
Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.
- Disconnect the fuel line - 1 - (black) and the ventilation line - 2 - (white) at the connecting point.
- Ignore - 3 -.
• Press in the securing ring to disengage the lines.
- Remove the right rear wheel.
- Remove the right rear wheel housing liner.
- Disconnect the vent and vacuum lines - arrows - from the Evaporative Emission (EVAP) canister.
- Unclip the wheel speed sensor wire - arrows - from the retainer on the filler neck.
- Remove the fuel filler door and the cap for the fuel filler neck.
- Disconnect the ground wire from the tank filler tube.
- Remove the fuel filler tube bolts - arrows -.
- Remove the bolt - 1 -.
- Remove the tensioning straps and bolts - arrows -. Support the fuel tank using the engine/transmission jack (V.A.G 1383 A) while doing so
Installing
- With a second technician assisting, guide the fuel filler neck between the rear subframe and chassis. Then place the fuel tank on the engine and transmission jack (V.A.G 1383 A).
- Lift the fuel tank slowly up to the installed position and secure it.
• To secure the fuel tank tensioning straps, only bolts with loose washers may be used. If other bolts are used, the straps could twist when the bolts are tightened.
- Tighten the new bolts for the tensioning straps - arrows - and the new bolt - 1 - to 25 Nm.
- Tighten the bolts - arrows - for the fuel filler neck to 8 Nm + 90° (1/4) additional turn.
Installation is performed in reverse order of removal. When doing this note the following:
• Make sure the vent and fuel lines are not kinked.
• Check the fuel tank/body ground connection on the filler tube.
• Make sure the line connections are securely fastened.
• After installing the fuel tank, check that the supply and vent lines are still clipped onto the fuel tank.