Fuel System Components
Fuel System Components
• Fuel hoses at the engine may only be secured with spring-type clamps appropriate for the model type.
• Spring type clip pliers (VAS 5024 A) or hose clip pliers (V.A.G 1921) are recommended for installing spring clamps.
• If the fuel delivery unit was replaced, then it is necessary to adapt the Engine Control Module (ECM) to the fuel pump. Refer to "Guided Functions" in the vehicle diagnosis, testing and information system VAS 5051.
=> [ Fuel Delivery Unit ]
=> [ Fuel Level Sensor (G) ]
Eos => [ Fuel Tank ]
Fuel Delivery Unit
Special tools, testers and auxiliary items required
• Wrench (T10202)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
Removing
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 as necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
• Read the safety precautions before starting. Refer to => [ Safety Precautions ] Safety Precautions.
• Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Remove the rear bench seat.
- Remove the cover - 1 - and the fuel pump control module - 2 - from the fuel delivery unit.
Fuel system is under pressure!
• Always wear protective eye-wear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
• Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.
- Disconnect the connector - arrow -.
- Remove the fuel lines - 1 and 2 - from the flange.
• Press the locking ring to release the fuel lines.
- Remove the locking ring using the wrench (T10202) and raise the flange slightly.
- Pull the delivery unit and seal out of the fuel tank opening.
• If the delivery unit is to be replaced then drain the old delivery unit before disposal.
• Follow disposal regulations.
Installing
- Replace the seal.
- Install the fuel delivery unit seal into the fuel tank opening dry.
- Lubricate the inner side of the seal with fuel.
- When installing the fuel delivery unit, be sure not to bend the fuel level sensor arm.
- Press the locking flange down and bring it into its installed position.
• The tab - 2 - on the flange must lie between tabs - 1 and 3 - on the fuel tank.
• The - arrow - points in the direction of travel.
- Tighten the locking ring.
• Tightening specification: 110 Nm
- Connect the supply line - 1 - (black).
- Connect the return line - 2 -. It is blue or has a blue mark.
- Connect the connector - arrow -.
- Pull on the couplings and connectors to make sure they are securely fastened.
The rest of the installation is performed in the reverse order of removal. When doing this note the following:
• The - arrow - on the cover points in the direction of travel.
Fuel Level Sensor (G)
• Phased-in introduction of fuel delivery units with a changed fuel level sensor.
Removing (Old Version)
- Remove the fuel delivery unit. Refer to => [ Fuel Delivery Unit ].
- Note the color of the wires for installing later.
- Release the connectors - arrows - and remove the electrical wires - 1, 2 and 3 -. Bend the hooks back.
- Lift the retaining tabs - 4 and 5 - with a screwdriver and pull the fuel level sensor downward and off - arrow -.
Installing
- Insert the fuel level sensor in the guides on the fuel delivery unit and push upward until it engages.
- Connect the wires - 1 through 3 -. Pay attention to the color.
- Pull on the connectors to make sure they are secure.
- Install the fuel delivery unit. Refer to => [ Fuel Delivery Unit ].
Removing (New Version)
- Remove the fuel delivery unit. Refer to => [ Fuel Delivery Unit ].
- Pull the fuel level sensor slightly to the side and upward at the same time.
- If the sensor cannot be released this way, then press the retaining tabs - arrows - to the side slightly.
- Note the color of the wires for installing later.
- Disconnect the connectors - 1 through 3 -. Bend the hooks back.
Installing
- Connect the wires - 1 through 3 -. Pay attention to the color.
- Pull on the connectors to make sure they are secure.
- Insert 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, Eos
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 starting. Refer to => [ Safety Precautions ] Safety Precautions.
- Drain the fuel tank as necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
- Remove the rear bench seat.
- Remove the cover - 1 - and the fuel pump control module (J538) - 2 - from the fuel delivery unit.
- Disconnect the 5 pin connector - arrow - from the flange.
- Remove the bolt for the fuel flap unit and remove the fuel flap unit.
- Remove the tension struts - A and B -. .
- Remove the center and rear mufflers.
- Remove the center muffler heat shield.
- Remove the right rear wheel.
- Remove the right rear wheel housing liner.
- Unclip the electrical wire - 1 - from the filler connection.
- Disconnect the ventilation line - 3 -.
- Remove the fuel filler tube bolts - 2 -.
- Disconnect the ventilation line - 1 - (white) and vacuum line - 2 - (green) for the leak detection pump (V144) behind the fuel tank by pressing in the clips.
Fuel system is under pressure! Always wear protective eye-wear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully pulling hose off connection.
- Disconnect the vent line - 1 - (white) and fuel line - 2 - (black) at the connecting point.
• Press the locking ring to release the lines.
• The vacuum line (green) for the leak detection pump must also be disconnected.
- Remove the tensioning strap bolts - arrows - and straps. Support the fuel tank using the engine/transmission jack (V.A.G 1383 A) while doing so
- Carefully lower the fuel tank.
Installing
Install in reverse order of removal. When doing this note the following:
• Only use bolts with loose washers to secure the fuel tank straps. The straps could twist when the bolts are tightened if other bolts are used.
• Make sure the vent and fuel lines are not kinked.
• Do not confuse the supply line and the return line (the return line is blue and the supply line is black).
• Make sure the line connections are securely fastened.
• Check the fuel tank/body ground connection on the filler tube.
- Install the tension struts.
Tightening Specifications
1 replace