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Home >> Volkswagen >> 2009 >> GLI 2.0 J, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 196 (2.0L - Fuel Supply - Engine Code(S): BPY (A5 Platform)) >> 20 Fuel Supply >> Description And Operation >> Fuel Tank And Components Assembly Overview

Fuel Tank And Components Assembly Overview

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Fuel Tank, (Engine Codes BGP, BGQ), Assembly Overview
GWWM20-0234Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Bolt, 1.5 Nm 
  2. Ground Connection 
    • Ensure the connection is securely seated.
  3. Vacuum Line 
    • To the Leak Detection Pump (LDP).
  4. Bolt, 10 Nm 
  5. Rivet 
  6. Protective Plate 
    • Riveted to the lower clamp at the factory.
    • When replacing the fuel tank, set the protective plate on the filler tube and rivet clamp (holes on the protective plate must align with the holes on the filler tube).
  7. Wiring Router 
    • For the Anti-lock Brake System (ABS) wire.
    • Clipped onto the protective plate.
  8. Bolt, 25 Nm 
    • Always replace.
  9. Fuel Tank 
    • Removing and installing, refer to FUEL TANK .
  10. Lock Washer 
  11. Bracket for Exhaust System 
  12. Mounting Strap 
    • Note the installed position.
  13. Heat Shield 
  14. Supply Line 
    • To the fuel rail.
    • Ensure the line is securely seated.
  15. Fuel Filter 
  16. Vacuum Line 
    • From the LDP to the intake manifold.
    • Clipped onto the fuel tank.
    • Ensure the line is securely seated.
  17. Vent Line 
    • From the Evaporative Emission (EVAP) canister to EVAP canister purge regulator valve.
    • Clipped onto the fuel tank.
    • Ensure the line is securely seated.
  18. Seal 
    • Always replace.
    • To install, place into the opening of the fuel tank dry.
    • Only lubricate the inner part with fuel when installing the fuel delivery unit.
  19. Fuel Delivery Unit 
    • Removing and installing, refer to FUEL DELIVERY UNIT .
    • Note the installed position in the fuel tank. Refer to Fig 2.
    • If the fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump. Refer to vehicle diagnosis, testing and information system VAS 5051 or vehicle diagnosis and service system VAS 5052.
    • Fuel pump, checking. Refer to FUEL PUMP, CHECKING .
    • Note the installed position on the fuel tank. Refer to Fig 2.
    • With fuel level sensor.
    • Fuel level sensor removing and installing. Refer to FUEL LEVEL SENSOR .
    • Clean the strainer if contaminated.
  20. Locking Ring, 110 Nm 
    • Ensure the ring is securely seated.
    • Use the wrench T10202 for removal and installation.
  21. Return Line 
    • Blue
    • Clipped onto the side of the fuel tank.
    • Ensure the line is securely seated.
  22. Cap 
    • Replace gaskets if damaged.
  23. Fuel Filler Door Unit 
  24. To Evaporative Emission (EVAP) canister 
  25. Supply Line 
    • Black
    • Clipped onto the side of the fuel tank.
    • Ensure the line is securely seated.
Fig 2: Identifying Installation Position Of Fuel Delivery Unit
GWWA20-1078Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

-Arrow- points in direction of vehicle travel.

Fuel delivery unit can only be installed in this position.

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