Fuel tank with attachments: Notes

WARNING: This page is about a different car, the 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, 2004 Volkswagen Jetta, and 2004 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

After completing repairs on the fuel delivery unit and/or the fuel gauge, ensure that the fuel supply and fuel return lines do not touch the fuel tank (transfer of pump noises).

Fig 1: Exploded View - Gas Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Sealing cap

With securing clip

2 - Seal

Replace if damaged

3 - Securing bolt

4 - Tank flap unit

With rubber cup and overflow hose
When installing: Push overflow hose behind filler neck and ensure it is not kinked

5 - Ground connection

Check for secure seating

6 - O-ring

Replace if damaged.

7 - Breather valve

To remove valve unclip sideways out of support
Before installing remove sealing cap
Checking

8 - 10 Nm

9 - Breather line

Clipped onto top of fuel tank
Check for secure seating
Secure with spring-type clips

10 - Clamping washer

11 - Heat shield

For fuel tank

12 - Fuel tank cover

Not installed on Jetta Wagon

13 - Fuel tank cover

14 - 25 Nm

15 - Securing strap

Note differing lengths

16 - Fuel tank

Support with engine/transmission jack V.A.G 1383 A when removing
Removing and installing. Refer to Fuel tank, removing and installing

17 - Seal

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

18 - Fuel delivery unit

Note installed position of flange on fuel tank
Removing and installing. Refer to Fuel delivery unit, removing and installing
Checking fuel pump. Refer to Fuel pump, checking
With fuel gauge sender - G -

Removing and installing fuel gauge sender. Refer to Fuel gauge sender, removing and installing
Clean strainer if soiled

19 - Union nut

Remove and install using wrench 3217

20 - Supply line

Black
Clipped onto fuel tank
Check for secure seating
Press release button on connecting piece to pull off flange

21 - Return hose

From fuel cooler
To connection "R"
Blue or with blue marking
Clipped onto fuel tank

Check for secure seating
Press release button on connecting piece to pull off flange

22 - Gravity/overflow valve

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

23 - Angle piece