Fuel Tank And Attachments Overview

Fig 1: Identifying Assembly Overview: Fuel Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1. Bolt 
2. Ground Connection 
   • Make sure it is secure.
3. Vacuum Line 
   • To the leak detection pump -V144-.
4. Bolt 
   • 10 Nm
5. Rivet 
6. Protective Plate 
   • Riveted to the lower clamp at the factory.
   • When replacing the fuel tank, lay the protective plate on filler tube and rivet clamp.
7. Wire Bracket 
   • Clipped onto the protective plate.
8. Bolt 
   • 25 Nm
   • Always replace
   • To secure the fuel tank straps, only bolts with loose washers may be used. If other bolts are used, the straps could twist when the bolts are tightened. Bolt allocation.
9. Fuel Tank 
   • Support using the engine-/gearbox jack -V.A.G 1383 A- when removing.
   • Removing and installing, refer to FUEL TANK .
10. Retainer 
11. Bracket for Exhaust System 
12. Securing Strap 
    • Note the installed position.
13. Heat Shield 
14. Supply Line 
    • To the fuel rail.
    • Make sure it is secure.
15. Fuel Filter 
    • Installed location, refer to Fig 3.
    • Arrow points in the direction of flow.
16. Vacuum Line 
    • From the leak detection pump to the intake manifold.
    • Clipped to the fuel tank.
    • Make sure it is secure.
17. Vent Line 
    • From the Evaporative Emission (EVAP) canister to the EVAP canister purge regulator valve 1 -N80-.
    • Clipped to the side of the fuel tank.
    • Make sure it is secure.
18. Seal 
    • Always replace.
    • To install, place into the fuel tank opening dry.
    • Lubricate with fuel only when installing the flange.
19. Fuel Delivery Unit 
    • Removing and installing, refer to FUEL DELIVERY UNIT .
    • If the fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump. Refer to "Guided Functions" in the vehicle diagnostic tester.
    • Checking the fuel pump. Refer to FUEL PUMP, CHECKING .
    • Note the installed position on the fuel tank. Refer to Fig 2.
    • With the fuel level sensor -G-.
    • Fuel level sensor removing and installing. Refer to Fuel Level Sensor -G- .
    • Clean the strainer if contaminated.
20. Lock Ring 
    • 110 Nm
    • Make sure it is secure.
    • Use the wrench -T10202- for removal and installation.
21. Return Line 
    • Blue
    • Clipped to the side of the fuel tank.
    • Make sure it is secure.
22. Cap 
    • Replace if damaged.
23. Fuel Filler Door Unit 
    • With a rubber seal.
    • Removing and installing, refer to Removal and Installation .
24. to the EVAP Canister 
25. Supply Line 
    • Black
    • Clipped to the side of the fuel tank.
    • Make sure it is secure.

Fig 2: Identifying Fuel Delivery Unit, Installed Position

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• The tab -2- on the flange must lie between the tabs -1 and 3- on the fuel tank.
• The -arrow- points in the direction of travel.

Fig 3: Identifying Fuel Filter Installation Position

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The pin -2- on the filter housing must engage in the recess in the bracket -1-.