Installing Fuel Line

Information 

• The description applies to all engine types. 
• The setup and procedures required may differ slightly from the illustrations or procedures described due to engine-specific differences. 

1. Position the vehicle-specific wire harness on the tank and in the engine compartment → .
   1. 1.1. Secure the wire harness with the line brackets. .
      Fig 1: Identifying Fuel Line Routing On Underbody

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Route the line connections for the tank flange.
   1. Pressure line (supply)
   2. Line for auxiliary heating
      Fig 2: Identifying Line Connections For Tank Flange

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3. Fit rapid-action coupling(s) at the tank flange -1-  or -1 and 2-  .
   Fig 3: Locating Fuel Supply And Connection Points Without Auxiliary Heating

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   Fig 4: Locating Tank Flange With Connection For Auxiliary Heating

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4. Raise the fuel tank using transmission jack V.A.G. 1383 A WE 1082  .

   → 201019 REMOVING AND INSTALLING FUEL TANK ON DFI ENGINES .

   1. 4.1. Position covers and secure restraining straps with the M8 screws.

      Tighten screws to the specified torque.

      → Tightening torque: 23 Nm (17 ftlb.) 

5. Fit heat shields.
   1. 5.1. Tighten three M6 collar nuts -3-  and one M6 screw -2-  to the specified torque.

      → Tightening torque: 10 Nm (7.5 ftlb.) 

      Fig 5: Identifying Underbody Heat Shields And Mounting Screw

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6. Fit heat shield -1-  on cardan shaft.
   1. 6.1. Tighten two M6 screws -2-  and one M8 collar nut -3-  to the specified torque.

      → Tightening torque: 10 Nm (7.5 ftlb.) 

      → Tightening torque: 20 Nm (15 ftlb.) 

      Fig 6: Identifying Cardan Shaft Heat Shield And Mounting Bolt

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7. Route fuel lines in the engine compartment.
   1. Plastic cover
   2. Fuel pressure line
   3. Connection for tank ventilation
   4. Line for leakage diagnosis pump
      Fig 7: Identifying Fuel Line Connection Points In Engine Compartment

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Connect fuel lines in the engine compartment.
   1. 8.1. Connect tank ventilation line -2-  . Listen for a clearly audible locking noise.

      Pull to check that the line is secure.

   2. 8.2. Connect connection for leakage diagnosis pump -3-  if it is used.
   3. 8.3. Fit the fuel pressure line (supply) -4-  as described in the next step.
      Fig 8: Identifying Plenum Panel Lines

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9. Screw on fuel pressure line.
   Fig 9: Identifying Threaded Joint For Fuel Pressure Line (Supply)

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   1. 9.1. Align the markings on the threaded connection -2-  .
   2. 9.2. Hold the connecting line -1-  for the fuel collection pipe securely and screw in counterpart component -3-  .
   3. 9.3. Tighten the threaded joint to the specified torque and counter at the hexagon on the connecting line -1-  at the same time using an open-ended wrench (a/f 19).

      → Tightening torque: 35 Nm (26 ftlb.)+/-10 % 

10. Fit plastic cover -1-  .
    1. Plastic cover
    2. Fuel pressure line
    3. Connection for tank ventilation
    4. Line for leakage diagnosis pump
       Fig 10: Identifying Fuel Line Connection Points In Engine Compartment

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.