Volkswagen Workshop Service and Repair Manuals

Note:

After all repairs to the fuel supply unit or the fuel gauge sender unit have been carried out, ensure the the supply or return flow hoses do not make contact with the fuel tank (pump noises may be transferred).

• Cap
• ◆ Renew seal if damaged
• Retaining ring
• Rubber cup
• Earth connection
• O-ring
• ◆ Renew if damaged
• Vent valve
• ◆ Checking , Fig.2
• Union nut

• Reservoir
• ◆ Type shown: Estate
• ◆ Basic expansion tank in saloon
• Vent pipe
• ◆ Filling vent
• Vent pipe
• ◆ Operating vent
• ◆ Only Estate
• Return pipe
• ◆ Blue
• ◆ From fuel manifold or injection unit

=> Repair group 24; mixture preparation, injection

• Union nut
• ◆ Remove and install with 3217
• Flange
• ◆ Note fitting position on fuel tank , Fig. 1

• Supply hose
• Sealing ring
• ◆ Coat with fuel when installing
• ◆ Renew if damaged
• Return hose
• Fuel gauge sender
• Fuel delivery unit
• ◆ Removing and installing
  => Page 20-13
• ◆ Checking fuel pump
  => Page 20-14
• 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
• ◆ Black
• ◆ To fuel manifold or injection unit

=> Repair group 24; mixture preparation, injection

• Fuel filter
• ◆ Fitting position: Arrow points in direction of flow
• Retaining clip
• 10 Nm

• Breather pipe
• ◆ To activated charcoal filter
  AEK , Item 6
• ◆ On vehicles without activated charcoal filter system to rubber cup -Item 3 -
• Gravity valve
• ◆ To remove valve unclip upwards out of filler neck
• ◆ Check valve for through-flow
  valve vertical: open,
  valve tilted 45 °: closed

→ 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