Fuel System Components
Fuel System Components
• Fuel hoses to engine may only be secured with spring type clamps appropriate for the model type. Refer to the parts catalog.
• Spring type clip pliers (VAS 5024A) or hose clip pliers (V.A.G 1921) are recommended for installing spring clamps.
• If the fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump. Refer to "Guided Functions" in the vehicle diagnostic tester.
=> [ Fuel Delivery Unit ]
=> [ Fuel Level Sensor ]
GTI => [ Fuel Tank ]
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
CAUTION!
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 if necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Safety Precautions.
• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Remove the rear seat bench.
- Remove the cover - 1 - and the fuel pump control module - 2 - from the fuel delivery unit.
CAUTION!
The fuel system is under pressure!
• Wear protective goggles and protective clothing to prevent injuries and contact with skin.
• Before disconnecting the connection, place a cloth around the connection point. Then release pressure by carefully disconnecting the connection.
- Disconnect the connector - arrow - from the flange.
- Disconnect the fuel lines - 1 and 2 - from the flange.
• Press in the securing ring to disengage the fuel lines.
- Remove the locking ring using (T10202) and lift the flange slightly.
- Pull the delivery unit and seal out of 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 opening in the fuel tank dry.
- Lubricate the inner side of the seal with fuel.
- When installing fuel delivery unit, be sure not to bend the fuel level sensor float arm.
- Press the locking flange down and bring it into the installed position.
• The tab - 2 - on the locking flange must lie between the tabs - 1 and 3 - on the fuel tank.
• - Arrow - points in direction of travel.
- Tighten the locking ring.
• Tightening specification: 110 Nm
- Connect the supply line - 1 - (black) to the flange.
- Connect the return line - 2 - (blue or with a blue mark) to the flange.
- Connect the connector - arrow -.
- Pull on the couplings and connector 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
• Phased-in introduction of fuel delivery units with changed fuel level sensor (G).
Old version, refer to.
New version, refer to.
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 through 3 -. Bend the retaining hooks on the connector back.
- Lift the retaining tabs - 4 and 5 - with a screwdriver and pull the fuel level sensor (G) downward and off - arrow -.
Installing
- Install the fuel level sensor in the guides on the fuel delivery unit and push upward until it engages.
- Connect the connectors - 1 through 3 -. Note the color coding.
- Pull on the connectors to make sure they are securely fastened.
- 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 (G) slightly to the side and simultaneously upward.
- If the sensor cannot be released this way, press the retaining tabs - arrows - to the side slightly.
- Note the colors of the wires for installing later.
- Disengage the electrical connectors - 1 through 3 - and disconnect them. Bend the retaining hooks on the connector back.
Installing
- Connect the connectors - 1 through 3 -. Note the color coding.
- Gently pull on the connectors to make sure it is securely fastened.
- Install the fuel level sensor in 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
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 ] Safety Precautions.
- Drain the fuel tank if necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
- Remove the rear seat bench.
- Remove the cover - 1 - with the fuel pump control module (J538) - 2 - from the fuel delivery unit.
- Disconnect the 5 pin connector - arrow - from the flange.
- Remove the right rear wheel.
- Remove the right rear wheel housing liner.
- Remove the fuel filler door unit.
- Disconnect the hoses - 1 and 2 -.
- Remove the filler pipe to body bolts - arrows -.
- Unclip the electrical wire from the filler pipe.
- Remove the center and rear mufflers.
- Remove the heat shield from the center and rear mufflers.
CAUTION!
The fuel system is under pressure!
• Wear protective goggles and protective clothing to prevent injuries and contact with skin.
• Before disconnecting the connection, place a cloth around the connection point. Then release pressure by carefully disconnecting the line connection.
- Disconnect the vent line - 1 - (white) and fuel line - 2 - (black) at the connecting point.
• Press in the securing ring to disengage the lines.
• Vacuum line (green) for the Leak Detection Pump (LDP) (V144) must also be disconnected.
- Remove the tensioning straps and bolts. Support the fuel tank using (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:
• To install 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.
• Make sure the vent and fuel lines are not kinked.
• Do not interchange supply and return lines (return line is blue or with a blue mark, supply line is black).
• Pull on the line connections to make sure they are securely fastened.
• Check the Ground (GND) connection of the fuel tank/chassis at the filler tube.
• If fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump. Refer to "Guided Functions" in the vehicle diagnostic tester.
Tightening Specifications
1 replace
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 ] Safety Precautions.
- Drain the fuel tank if necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
- Remove the rear seat bench.
- Remove the cover - 1 - with the fuel pump control module (J538) - 2 - from the fuel delivery unit.
- Disconnect the 5 pin connector - arrow - from the flange.
- Remove the fuel tank door 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 from the filler tube connection - 1 -.
- Disconnect the ventilation line - 3 -.
- Remove the fuel filler tube bolts - 2 - from the body.
- Disconnect the ventilation line - 1 - (white) and vacuum line - 2 - (green) for the Leak Detection Pump (LDP) (V144) behind the fuel tank by pressing in the circlips.
CAUTION!
The fuel system is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then release pressure by carefully disconnecting the connection.
- Disconnect the vent line - 1 - (white) and fuel line - 2 - (black) at the connecting point.
• Press in securing ring to disengage the lines.
• Vacuum line (green) for the LDP must also be disconnected.
- Remove the tensioning straps and bolts - arrows -. Support the fuel tank using (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:
• To install 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.
• 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 Ground (GND) connection of the fuel tank/chassis at the filler tube.
- Install the tension struts.
Tightening Specifications
1 replace