Fuel tank, fuel filler and attachments, removing and installing: Notes

Fig 1: Exploded View Of Fuel Tank, Fuel Filler And Attachments

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Sealing cap

2 - Seal

• Replace if damaged

3 - Securing bolt

4 - Tank flap unit

• With rubber cup

5 - Breather line

• Black
• Check if seated securely
• Clipped onto top of fuel tank

6 - Ground connection

• Check if seated securely

7 - Breather line

• White
• Check for secure seating
• Press together at front to release

8 - Gravity valve

• To remove valve unclip upward out of support
• Check valve for through flow

Valve vertical: Open

Valve tilted 45 ° : Closed

9 - Seal

• Replace if damaged

10 - Change-over valve

• To remove valve unclip sideways out of socket
• Checking Checking change-over valve 

11 - Breather line

• Black
• Check for secure seating

12 - Pressure retention valve

• Checking Checking pressure retention valve  under Fuel tank, fuel filler and attachments, removing and installing 

13 - Breather line

• Black
• Check for secure seating

14 - Fuel tank

• When removing, support with Engine and gearbox jack VAG 1383 A
• Removing and installing → Fuel tank, removing and installing 

15 - Clamping washer

16 - Heat shield

• For fuel tank

17 - 25 Nm

18 - Clamping nut, 2 Nm

19 - Fuel tank cover

20 - Securing strap

• Note differing lengths
• Installation position: Fixing point (holes) point in direction of travel (forward)

21 - Supply line

• Black
• Check for secure seating
• To pull off of fuel filter press release buttons on connecting piece
• To fuel supply pipe on fuel rail: → 24 MULTIPORT FUEL INJECTION (MFI)

22 - Fuel filter

• Installation position: Arrow points in direction of flow

23 - Screw-type clip

• Observe installation position Installation position of screw-type clip for fuel filter  under Fuel tank, fuel filler and attachments, removing and installing 

24 - Breather line

• White
• Check for secure seating
• Clipped onto side of fuel tank
• To EVAP canister purge regulator valve N80

25 - Seal

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

26 - Fuel delivery unit

• Observe installation position of flange on fuel tank Installation position of fuel delivery unit flange 
• Removing and installing → Fuel delivery unit , removing and installing 
• Removing and installing fuel gauge sender → Fuel gauge sender, removing and installing 
• Checking fuel pump → Fuel pump, checking 

• Clean strainer if soiled

27 - Union nut, 75 Nm

• Remove and install with Ring Nut Spanner 3217

28 - Supply line

• Black
• Check for secure seating
• Clipped onto side of fuel tank
• When puling off flange and fuel filter press release button on connecting piece

29 - Return line

• Blue or with blue marking
• Clipped onto side of fuel tank
• Check for secure seating
• To remove from flange press release button on connecting piece

• From fuel return pipe on fuel rail: → 24 MULTIPORT FUEL INJECTION (MFI)

30 - Connector

• Black, 4-pin
• For Sender for fuel gauge - G  - and Fuel Pump (FP) G6

31 - 10 Nm