Removing and installing fuel tank with attachments and fuel filter: engine code AJH — VW

Removing and installing fuel tank with attachments and fuel filter: engine code AJH
Note
Ensure, on completion of all work on the fuel delivery unit and fuel gauge that the fuel supply and fuel return hoses do not touch the fuel tank (transfer of pumping noises).
Cap
Seal
If damaged only renew together with cap.
Clamping ring
Rubber cup
Gravity valve
To remove valve unclip upwards out of filler neck
Check valve for through-flow. Valve vertical: open. Valve tilted 45°: closed
O-ring
Renew if damaged.
Breather valve
Cannot be removed, renew only together with filler neck
Item
Check
Fig.
.
Pressure retention valve
For fuel tank breather.
Checking
Fig.
,
Fig.
.
Return line
Blue
Check for secure seating.
Clipped onto fuel tank.
From fuel return pipe on fuel rail
Rep. gr.
24
.
Union nut, 75 Nm
Remove and install using
union nut tool
3217
.
Connector
Black, 4-pin.
For
fuel gauge sender
G
and
fuel pressurisation pump
G6
.
Flange
Note installation position on fuel tank
Fig.
.
Letters
„V“
and
„R“
stamped on underside for supply hose (Vorlauf) and return hose (Rücklauf)
Supply hose
Check for secure seating.
Seal
Renew.
When installing, fit dry in fuel tank opening.
Moisten with fuel only when installing flange
Item
.
Return hose
Check for secure seating.
6 Nm
Filler neck
With expansion tank and breather valve
Breather line
Check for secure seating.
To junction piece between activated charcoal filter and activated charcoal filter solenoid valve 1
Anchor
, Repairing parts of activated charcoal filter system: engine code AJH
Seal
Renew if damaged.
Clamping ring
Non-return valve
Check for ease of movement
Breather line
Check for secure seating.
25 Nm
Fuel tank
When removing, support using
engine and gearbox jack
V.A.G 1383 A
.
Securing strap
Note different lengths.
Note installation position.
20 Nm
Bracket
For fuel filter.
Supply line
Black
Check for secure seating.
To fuel supply pipe on fuel rail
Rep. gr.
24
.
Fuel filter
Installation position: arrow indicates direction of flow.
Fuel gauge sender
G
Fuel delivery unit
Removing and installing
Chapter
.
Checking fuel pump
Chapter
.
Filter strainer
Clean strainer if soiled.
Installation position of fuel delivery unit flange
Marking on flange must align with marking on fuel tank
arrows
.
Note
After installing fuel delivery unit flange, check that supply, return and breather lines are still clipped onto fuel tank.
Checking breather valve
Valve in rest position: closed
Valve pushed in direction of arrow: open
Checking pressure retention valve
From gravity valve the pressure retention valve is open in both directions of flow
arrow 1
.
From junction piece between activated charcoal filter/activated charcoal filter solenoid valve 1, it is only open in one direction of flow
arrow 2
.