Removing and installing fuel tank with attachments and fuel filter: vehicles with front-wheel drive — VW

Removing and installing fuel tank with attachments and fuel filter: vehicles with front-wheel drive
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
With securing clip.
Seal
Renew if damaged.
Tank flap unit
With rubber cup.
Securing bolt
Gravity valve
To remove valve unclip upwards out of support.
Check valve for through-flow; valve vertical: open, valve tilted 45°: closed.
O-ring
Renew if damaged.
Breather line
Black
Clipped onto side of fuel tank.
Check for secure seating.
Secure with spring-type clips.
To activated charcoal filter
Item
.
Breather valve
To remove valve unclip sideways out of support.
Before installing remove cap
Item
.
Check
Fig.
.
Earth connection
Check for secure seating.
Supply line
Black
Check for secure seating.
Clipped onto side of fuel tank.
To release lower securing clip, press together circlip on face side of angled connection.
Between flange
Item
and fuel filter -item
Item
-
Return line
Blue or with blue marking.
Clipped onto side of fuel tank.
Check for secure seating.
To release lower securing clip, press together circlip on face side of angled connection.
From fuel return pipe on fuel rail:
Repairing injection system
Rep. gr.
24
Dismantling and assembling fuel rail and injectors
.
Connector
Black, 4-pin.
For
fuel gauge sender
G
and
fuel pump
G6
.
Union nut, 80 Nm
Remove and install using
union nut tool
3217
.
Flange
Only renew complete with fuel supply unit.
Note installation position on fuel tank
Fig.
.
Fuel gauge sender
G
Clipped onto fuel delivery unit reservoir.
Return line
Check for secure seating.
Between flange
Item
and fuel delivery unit reservoir.
Supply line
Check for secure seating.
Between flange
Item
and fuel delivery unit -item
Item
-.
Fuel delivery unit
Can only be renewed complete with flange.
Removing and installing
Chapter
.
Checking fuel pump
Chapter
.
Clean strainer if soiled.
Seal
Renew if damaged.
When installing, fit dry in fuel tank opening.
Moisten with fuel only when installing flange.
25 Nm
Fuel tank
When removing, support using
engine and gearbox jack
V.A.G 1383 A
.
Removing and installing
Chapter
.
Bracket
For securing straps.
Note installation position.
Securing strap
Note different lengths.
Installation position: Fixing point (holes) face in direction of travel.
Retaining ring
Secured to body.
10 Nm
Fuel filter
Installation position: arrow points in direction of flow.
Supply line
Black
Check for secure seating.
Secure with spring-type clips.
To fuel supply pipe on fuel rail
Repairing injection system
Rep. gr.
24
Dismantling and assembling fuel rail and injectors
Breather line
Check for secure seating.
Clipped onto top of fuel tank.
Installation position of fuel delivery unit flange
Mark on flange
1
must align with mark on fuel tank
2
.
Note
After installing fuel delivery unit flange, check that supply, return and breather lines are still clipped onto fuel tank.
Checking breather valve
Lever in rest position: closed.
Lever pushed in direction of arrow: open.
Note
Before installing breather valve remove fuel tank cap.