Removing and installing fuel tank with its attachments and fuel filter — VW

Sealing cap
Seal
Renew if damaged

Securing screw
Tank flap unit
With rubber cup

10 Nm
O-ring
Vent valve
To remove valve unclip sideways out of support
Before installing, remove cap item
1
Checking =>Fig.
2

Vent pipe
Clipped onto top of fuel tank
Check securely seated
Secure with spring-type clips

From activated charcoal filter canister
Guide for wiring/pipes/hoses
In longitudinal member

Vent pipe
Check securely seated
Secure with spring-type clips

Fuel tank
Support with engine and gearbox jack V.A.G 1383 A when removing
Removing and installing
=> Page
20-18

Heat shield
For fuel tank

Clamping washer
Fuel tank cover
With securing clip

25 Nm
Securing strap
Note differing length
Installation position: Fixing point (holes) point in direction of travel

Fuel filter
Fitting position: Arrow points in through-flow direction

Screw-type clip
Note installation position =>Fig.
3

Vent pipe
Check securely seated
Secure with spring-type clips
To activated charcoal filter canister
=>Page
20-46
, item
1

Supply pipe
Black
Check securely seated
To fuel supply pipe on fuel rail:

=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail and injectors
5-Cyl. Injection Engine (4 Valve), Mechanics
Servicing injection system
Dismantling and assembling fuel rail and injectors

Sealing ring
Renew if damaged
When installing, insert seal "dry" into fuel tank opening
Moisten with fuel only when installing flange

Fuel delivery unit
Note installation position of flange on fuel tank => Fig.
1
Removing and installing
=> Page
20-14
Checking fuel pump
=> Page
20-22
Clean strainer if soiled

Union nut, 80 Nm
Remove and install with spanner 3217

Supply pipe
Black
Check securely seated
Clipped onto side of fuel tank

Return pipe
Clipped onto side of fuel tank
Check securely seated
From fuel return pipe on fuel rail

=> Repair group 24; Servicing injection system; Dismantling and assembling fuel rail and injectors
5-Cyl. Injection Engine (4 Valve), Mechanics
Servicing injection system
Dismantling and assembling fuel rail and injectors

Gravity valve
To remove valve unclip upwards out of support
Check valve for through-flow
valve vertical: open,
valve tilted 45 °: closed

Vent pipe
To activated charcoal filter canister
=>Page
20-46
, item
1

Earth connection
Check securely seated

Fig. 1
Installation position of fuel delivery unit flange

Marking on flange must align with the marking on fuel tank -arrows-.

Blue or blue marked return pipe -1- to connection with identification
-R-.

Black supply pipe -2- to connection with identification -V-.

Note:

After installing fuel delivery unit flange, check that the supply, return and breather pipes are still clipped onto the fuel tank.

Fig. 2
Checking vent valve

Lever in rest position: Closed

Lever pushed in direction of arrow: Open

Note:

Before installing vent valve remove fuel tank cap.

Fig. 3
Installation position of screw clamp for fuel filter

Note:

The fuel filter in the illustration is shown from the front.

Install screw clamp -arrow- as shown in the illustration.

Ensure there is sufficient clearance between the clamp lock (tightening fixture) and fuel tank. Dimension "a" must be
less than 5 mm.