Removing and installing fuel tank with its attachments and fuel filter, four wheel drive — VW

Note:

After all work on the fuel delivery unit or the fuel gauge sender ensure that the supply/return hoses (partly corrugated pipes) item
13
and item
15
do not touch the fuel tank (transmission of pump noises).

Cap
Seal
If damaged only replace together with cap

Retaining 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

Vent valve
Cannot be removed, replace together with filler neck => item
17
Checking =>Page
20-14
, Fig.
2

Pressure retaining valve
For fuel tank venting
Checking => Page
20-15
, Fig.
3

Return pipe
Blue
From fuel manifold
Secure with spring-type clips
Check securely seated

=> Repair group 24; Motronic injection and ignition system; Servicing injection part
6-cyl. fuel injection engine, Mechanics
Motronic injection and ignition system
Servicing injection part

Union nut
Remove and install with 3217

Connector
Black, 4 pin
For fuel gauge sender (G) and fuel pump (G6)

Flange
Note fitting position on fuel tank => Page
20-14
, Fig.
1
Underside marked with "V" and "R" for supply and return hoses

Supply hose
Sealing ring
Coat with fuel when installing
Renew if damaged

Return hose
10 Nm
Filler neck
With expansion tank and vent valve
To remove remove brake pipe retaining clip
=> Page
20-15
, Fig.
4
Loosen right axle beam
=> Page
20-16
, Fig.
5

=> Repair group 42; Running gear assembly overview, Syncro rear axle beam
6-cyl. fuel injection engine, Mechanics
Running gear assembly overview, Syncro rear axle beam

Vent pipe
To junction piece between activated charcoal filter and solenoid valve 1
=>Page
20-33
, item
1

Boot
Renew if damaged

Retaining ring
Non-return valve
Check for freedom of movement

Vent pipe
25 Nm
Fuel tank
Support with engine and gearbox jack V.A.G 1383 A when removing
To remove pull filler neck out of tank
Remove brake pipe retaining clip
=> Page
20-15
, Fig.
4
Loosen right axle beam
=> Page
20-16
, Fig.
5

=> Repair group 42; Running gear assembly overview, Syncro rear axle beam
6-cyl. fuel injection engine, Mechanics
Running gear assembly overview, Syncro rear axle beam

Securing strap
Note differing length

20 Nm
Bracket
For fuel filter

Supply pipe
Secure with spring-type clips
Check securely seated
Black
To fuel manifold

=> Repair group 24; Motronic injection and ignition system; Servicing injection part
6-cyl. fuel injection engine, Mechanics
Motronic injection and ignition system
Servicing injection part

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

Fuel gauge sender (G)
Fuel delivery unit
Removing and installing
=> Page
20-22
Checking fuel pump
=> Page
20-24

Strainer

Fig. 1
Installation position of fuel delivery unit flange

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

Fig. 2
Checking vent valve

Valve in rest position: Closed

Valve pushed in direction of arrow: Open

Fig. 3
Checking pressure retaining valve

From the gravity valve direction the pressure retaining valve is open in both directions of flow -arrow -1-.

From the direction junction piece activated charcoal filter/solenoid valve 1 it is only open in one direction of flow -arrow -2-.

Fig. 4
Remove right brake pipe retaining clamp

Unhook brake pipe, do not open.

Fig. 5
Loosen axle beam

Remove bolts -arrow-