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 6340) or hose clip pliers (VAS 6362) are recommended for installing space saving clamps.
=> [ 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)
Requirement:
• The fuel tank may be a maximum of 3/4 full. This ensures the fuel level is below the fuel delivery unit flange.
Removing
• 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.
• Fuel tank and attachments overview. Refer to => [ Fuel Tank and Attachments Overview ] Fuel Tank and Attachments Overview.
- Remove the rear seat bench.
- Remove the cover - 1 - and the fuel pump control module (J538) - 2 - from the fuel delivery unit.
- First, pull on the connector - arrow - 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.
- Check the contacts on the connector and the fuel delivery unit for damage.
The fuel supply line is under pressure. Always wear protective eyewear 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. Remove the hose connection carefully to release the pressure.
- 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 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 new 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 ring down and bring it into its installed position.
• The tab - 2 - on the locking ring 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 lines 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 (G)
Removing
- Remove the fuel delivery unit. Refer to => [ Fuel Delivery Unit ].
- Pull the fuel level sensor slightly to the side and simultaneously upward.
- 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.
- Disengage the electrical connectors - 1 through 3 - and disconnect them. Bend the retaining hooks on the connectors back.
Installing
- Connect the connectors - 1 through 3 -. Note the color coding.
- Pull on the connectors to make sure they are securely fastened.
- 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 beginning work. Refer to => [ Safety Precautions ] Fuel Supply.
- Drain the fuel tank using the fuel extracting device (VAS 5190) , if necessary. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
- Remove the rear seat bench.
- Remove the cover - 1 - and the fuel pump control module (J538) - 2 - from the fuel delivery unit.
- Disconnect the connector - arrow -.
- 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 connections on the filler tube.
- Disconnect the ventilation line - 3 -.
- Remove the fuel filler tube to body bolts - 2 -.
- Press the securing ring in and disconnect the vent line - 1 - (white) behind the fuel tank.
- Press the securing ring in and disconnect the vacuum line - 2 - (green) for the leak detection pump (V144) behind the fuel tank.
Fuel system is under pressure! Always wear protective eyewear 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. Remove the hose connection carefully to release the pressure.
- Disconnect the vent line - 1 - (white) and the fuel line - 2 - (black) at the connecting point.
• Press in the securing ring to disengage the fuel line.
• The green leak detection pump vacuum line 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:
• 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.
• 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