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 ]
=> [ ]
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
Requirement:
• 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 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 assembly overview. Refer to one of the following: GTI, refer to => [ Fuel Tank and Attachments Overview ] Fuel Tank and Attachments Overview or Eos, refer to => [ Fuel Tank and Attachments Overview ] Fuel Tank and Attachments Overview.
- Remove the rear seat bench.
- Remove the cover - 1 - with 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 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! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then, disconnect the connection carefully to release the pressure.
- Remove the fuel lines - 1 and 2 - from the flange.
• Press in the securing ring to disengage the fuel lines.
- Remove the lock ring using (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 the installed position.
• The tab - 2 - on the locking flange must lie between tabs - 1 and 3 - on the fuel tank.
• - Arrow - points in direction of travel.
- Tighten the 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 connector to make sure they are fastened securely.
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, also press the retaining tab - arrows - to the side slightly.
- Note the color of the wire for installing later.
- Disengage 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.
- Pull on the connector to make sure it is fastened securely.
- Insert the fuel level sensor in the guide 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 ] Fuel Supply.
- Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.
- Empty the fuel tank using the fuel extracting device (VAS 5190) if necessary: Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
- Remove the seat bench. Refer to
- Remove the cover - 1 - with fuel pump control module (J538) - 2 - from the fuel delivery unit.
- Disconnect the connector - arrow -.
- Remove the right rear wheel.
- Remove the right rear wheel housing liner..
- Remove the bolt for the fuel flap unit and remove the fuel flap unit.
- Disconnect the hoses - 1 and 2 -.
- Remove the fuel filler tube bolts - arrows - from the body.
- Unclip the electrical wire from the filler connection.
- Remove the center and rear mufflers.
- Remove the heat shield from the center and rear mufflers.
The fuel supply line 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, disconnect the connection carefully to release the pressure.
• Press in the securing ring to disengage the fuel lines.
- Disconnect the vent line - 1 - (white) and fuel line - 2 - (black) at the connecting point.
• On USA/Canadian vehicles, the green Leak Detection Pump (LDP) (V144) vacuum line must also be disconnected.
- Remove the tensioning strap bolts and straps. Support the fuel tank using (V.A.G 1383 A) while doing so
- Lower the fuel tank.
Installing
Install in reverse order of removal. When doing this note the following:
Tightening specifications, refer to => [ Fuel Tank and Attachments Overview ] Fuel Tank and Attachments Overview.
• To mount 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 the supply and return lines (return line is blue or has blue marks, supply line is black).
• Pull on the line connections to make sure they are fastened securely.
• Check the ground (GND) connection of the fuel tank/chassis at filler tube.
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.
- Empty 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 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 rear right wheel housing liner..
- Unclip the electrical wire - 1 - from filler connection.
- Disconnect the ventilation line - 3 -.
- Remove the fuel filler tube bolts - 2 - from the body.
- 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 (LDP) (V144) behind the fuel tank.
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, disconnect the connection carefully to release the pressure.
- Disconnect vent line - 1 - (white) and fuel line - 2 - (black) at the connecting point.
• Press in the securing ring to disengage the fuel lines.
• Also disconnect the LDP vacuum line (green).
- 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 mount 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 fuel tank/chassis at filler tube.
- Install the tension struts.
Tightening Specifications
1 replace