Volkswagen Workshop Service and Repair Manuals

Note:

Please ensure after all repairs to the fuel supply unit and the fuel gauge sender, the corrugated hoses/hoses between delivery unit and fuel tank flange do not make contact with the fuel tank, otherwise pump noises will be transmitted.

• Cap
• Retaining ring
• Rubber cup
• O-ring
• ◆ Renew if damaged

• Gravity valve
• ◆ To remove, release locking lug and unclip valve upwards out of filler neck
• ◆ Check valve for through-flow
  valve vertical: open,
  valve tilted 45 °: closed
• Vent pipe
• ◆ To activated charcoal filter
  , Item 6
• ◆ On vehicles without activated charcoal filter system to rubber cup -Item 3 -
• Earth connection
• Vent valve
• ◆ Checking =>Fig.2
• ◆ To remove pull locking latch lightly to inside -arrow- and pull valve out

• Return hose/line
• ◆ Blue or with blue marking
• ◆ From injection unit or from fuel manifold

=> Repair group 24; Mixture preparation, injection

• Union nut, 75 Nm
• ◆ Remove and install with 3217
• Hose guide
• Flange
• ◆ Note fitting position on fuel tank => Fig. 1
• Supply hose/corrugated pipe
• ◆ When the flange is installed it must not contact the fuel tank, otherwise pump noises will be transmitted
• Sealing ring
• ◆ Coat with fuel when installing
• ◆ Renew if damaged

• Return hose/corrugated hose
• ◆ When the flange is installed it must not contact the fuel tank, otherwise pump noises will be transmitted
• Fuel delivery unit
• ◆ Removing and installing
  
• ◆ Checking fuel pump
  => Page 20-12
• Fuel gauge sender
• ◆ Adjusting adjustable type:

=> Current flow diagrams, Electrical fault finding and Fitting locations

• Strainer
• Securing strap
• ◆ Note differing length
• Bracket
• ◆ For securing straps
• 25 Nm

• Fuel tank
• ◆ Support with engine and gearbox jack V.A.G 1383 A when removing
• Supply pipe
• ◆ White arrow
• ◆ To injection unit or to fuel manifold

=> Repair group 24; Mixture preparation, injection

• Fuel filter
• ◆ Fitting position: Arrow points in direction of flow
• Retaining clip
• 20 Nm
• Bracket
• ◆ For fuel filter
• Rubber buffer
• Spring clip
• Spacer bush
• 10 Nm

→ Fig. 1     Installation position of fuel delivery unit flange

Marking on the flange must align with marking on the fuel tank.

→ Fig. 2     Checking vent valve

Lever in rest position: Closed

Lever pushed in direction of arrow: Open