Volkswagen Workshop Service and Repair Manuals

Assembly overview - Fuel tank with attachments and fuel filter Front-wheel drive vehicles → Anchor Four-wheel drive vehicles → Anchor Front-wheel drive vehicles

1 -

O-ring

q	Renew if damaged.

2 -	Gravity valve

q	To remove valve unclip upwards out of support.

q	Check valve for through-flow

q	Valve vertical: open

q	Valve tilted 45 °: closed

3 -	Breather line

q

White.

q	Check for secure seating.

q	Secure with spring-type clips.

q	To activated charcoal filter → Item.

4 -

Cap

q	With securing clip

5 -

Seal

q	Renew if damaged.

6 -	Securing bolt

7 -	Tank flap unit

q	With rubber cup.

8 -	Breather valve

q	To remove valve unclip sideways out of support.

q	Before installing remove sealing cap → Item.

q	Checking → Fig..

9 -	Earth connection

q	Check for secure seating.

10 -

10 Nm

11 -	Fuel tank filler neck

12 -	Breather line

q

Black

q	Clipped onto top of fuel tank.

q	Check for secure seating.

q	Secure with spring-type clips.

13 -

Fuel tank

q	When removing, support using engine and gearbox jack -V.A.G 1383 A-.

q	Removing and installing → Chapter.

14 -	Clamping washer

15 -	Heat shield

q	For fuel tank.

16 -

25 Nm

17 -

Lock nut

18 -	Fuel tank cover

19 -	Securing strap

q	Note differing lengths.

q	Installation position: Fixing point (holes) face in direction of travel.

20 -	Supply line

q

Black

q	Check for secure seating.

q	To fuel supply pipe on fuel rail → Chapter.

21 -	Fuel filter

q	Installation position: arrow points in direction of flow.

22 -	Screw-type clip

q	Note installation position → Fig..

23 -

Seal

q	Renew if damaged.

q	When installing, insert seal dry into fuel tank opening.

q	Moisten with fuel only when installing flange.

24 -	Fuel delivery unit

q	Note installation position of flange on fuel tank → Fig..

q	Removing and installing → Chapter.

q	Checking fuel pump → Chapter

q	Clean strainer if soiled.

25 -	Union nut, 80 Nm

q	Remove and install using union nut tool -3217-.

26 -	Supply line

q

Black

q	Check for secure seating.

q	Clipped onto side of fuel tank.

27 -	Return line

q	Blue or with blue marking.

q	Clipped onto side of fuel tank.

q	Check for secure seating.

q	From fuel return pipe on fuel rail → Chapter.

28 -	Overflow hose

Installation position of fuel delivery unit flange Mark on flange must align with mark on fuel tank -arrows-. Blue or blue marked return line -1- to connection marked -R-. Black supply line -2- to connection marked -V-.   Note After installing fuel delivery unit flange, check that supply, return and breather lines are still clipped onto fuel tank.

Checking vent valve Lever in rest position: closed Lever pushed in direction of arrow: open   Note Before installing vent valve remove fuel tank cap.

Installation position of fuel filter screw-type clip   Note In the illustration the fuel filter is shown from the front. –  Install screw-type clip -arrow- as shown in illustration. Ensure sufficient clearance between clip fastener and fuel tank. Dimension -a- must be at least 5 mm. Vehicles with four-wheel drive

1 -

Connector

q	Black, 4-pin

q	For fuel gauge sender -G- and fuel system pressurisation pump -G6-

2 -

Connector

q	Black, 2-pin

3 -	Bracket for return line

q	Clipped onto side of fuel delivery unit

4 -	Return line

5 -	Gravity valve

q	To remove valve unclip upwards out of support.

q	Check valve for through-flow valve vertical: open, valve tilted 45°: closed.

6 -	Breather line

q

White.

q	Check for secure seating.

q	Secure with spring-type clips.

q	To activated charcoal filter → Item.

7 -

O-ring

q	Renew if damaged.

8 -	Securing clip

9 -

Cap

10 -

Seal

q	Renew if damaged.

11 -	Securing bolt

12 -	Tank flap unit

q	With rubber cup.

13 -	Breather valve

q	To remove valve unclip sideways out of support.

q	Before installing remove sealing cap → Item.

q	Checking → Fig..

14 -	Earth connection

q	Check for secure seating.

15 -

10 Nm

16 -	Fuel tank filler neck

17 -	Union nut, 80 Nm

q	Remove and install using union nut tool -3217-.

18 -	Fuel gauge sender 2 -G169-

q	With suction jet pump: removing, installing and checking suction jet pump → Chapter

q	Observe installation position on fuel tank: mark on sender must align with mark on fuel tank

q	Checking: → Current flow diagrams, Electrical fault finding and Fitting locations

19 -

Seal

q	Renew if damaged.

q	When installing, insert seal dry into fuel tank opening.

q	Moisten with fuel only when installing flange.

20 -	Breather line

q

Black

q	Clipped onto top of fuel tank.

q	Check for secure seating.

q	Secure with spring-type clips.

21 -

Fuel tank

q	When removing, support using engine and gearbox jack -V.A.G 1383 A-.

q	Removing and installing → Chapter.

22 -

25 Nm

23 -	Securing strap

q	Note installation position.

24 -	Clamping washer

25 -	Heat shield

q	For fuel tank.

26 -	Retaining strut

27 -	Supply line

q

Black

q	Check for secure seating.

q	To fuel supply pipe on fuel rail → Chapter.

28 -	Fuel filter

q	Installation position: arrow points in direction of flow.

29 -	Screw-type clip

q	Note installation position → Fig..

30 -	Supply line

q	Check for secure seating.

31 -	Fuel delivery unit

q	With fuel gauge sender -G-

q	Note installation position of flange on fuel tank → Fig..

q	Removing and installing → Chapter.

q	Checking fuel pump → Chapter

q	Clean strainer if soiled.

32 -	Supply line

q

Black

q	Check for secure seating.

q	Clipped onto side of fuel tank.

33 -	Return line

q	Blue or with blue marking.

q	Clipped onto side of fuel tank.

q	Check for secure seating.

q	From fuel return pipe on fuel rail → Chapter.

34 -	Overflow hose

Installation position of fuel delivery unit flange Mark on flange must align with mark on fuel tank -arrows-. Blue or blue marked return line -1- to connection marked -R-. Black supply line -2- to connection marked -V-.   Note After installing fuel delivery unit flange, check that supply, return and breather lines are still clipped onto fuel tank.

Checking vent valve Lever in rest position: closed Lever pushed in direction of arrow: open   Note Before installing vent valve remove fuel tank cap.

Installation position of fuel filter screw-type clip   Note In the illustration the fuel filter is shown from the front. –  Install screw-type clip -arrow- as shown in illustration. Ensure sufficient clearance between clip fastener and fuel tank. Dimension -a- must be at least 5 mm.