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Safety precautions when working on fuel supply system > < Removing and installing fuel tank with attachments and fuel filter: engine code AJH

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Removing and installing fuel tank with attachments and fuel filter: engine code AWC
   
Removing and installing fuel tank with attachments and fuel filter: engine code AWC
  Note
t  Ensure, on completion of all work on the fuel delivery unit and fuel gauge that the fuel supply and fuel return hoses do not touch the fuel tank (transfer of pumping noises).
t  Fuel pump relay -J17- → Fig.
1 - Cap
2 - Securing clip
3 - Seal
q   Renew if damaged.
4 - Retaining ring
5 - Rubber cup
6 - Gravity valve
q   To remove valve unclip upwards out of filler neck
q   Check valve for through-flow; valve vertical: open, valve tilted 45 °: closed.
7 - O-ring
q   Renew if damaged.
8 - Breather valve
q   Cannot be removed, renew only together with filler neck → Item
q   Checking → Fig..
9 - Pressure retention valve
q   For fuel tank breather.
q   Checking → Fig..
10 - Return line
q   Blue
q   Check for secure seating.
q   Clipped onto fuel tank.
q   From fuel return pipe on fuel rail → Rep. Gr.24.
11 - Supply line
q   Black.
q   Check for secure seating.
q   Clipped onto fuel tank.
q   To fuel rail.
12 - Connector
q   Black, 4-pin
q   For fuel gauge sender -G- and fuel system pressurisation pump -G6-
13 - 6 Nm
14 - Filler neck
q   With expansion tank and breather valve
15 - Breather line
q   Check for secure seating.
q   To junction between activated charcoal canister and solenoid valve 1 for activated charcoal canister → Anchor, Repairing parts of the activated charcoal filter system: engine code AWC.
16 - Seal
q   Renew if damaged.
17 - Retaining ring
18 - Breather line
q   Check for secure seating.
19 - Non-return valve
q   Check for ease of movement
20 - 25 Nm
21 - Fuel tank
q   When removing, support using engine and gearbox jack -V.A.G 1383 A-
22 - Securing strap
q   Note different lengths.
q   Note installation position.
23 - 20 Nm
24 - Bracket
q   For fuel filter
25 - Supply line
q   Black.
q   Check for secure seating.
q   To fuel supply pipe on fuel rail → Rep. Gr.24.
26 - Fuel filter
q   Fitting position: arrow indicates direction of flow
27 - Union nut, 75 Nm
q   Remove and install using union nut tool -3217-
28 - Fuel delivery unit
q   Note installation position on fuel tank → Fig..
q   Removing and installing → Chapter.
q   Removing and installing fuel sender → Chapter.
q   Checking fuel pump → Chapter.
q   Clean strainer if soiled.
29 - Seal
q   Renew if damaged.
q   When installing, insert seal dry into fuel tank opening.
q   Moisten only for installation of fuel delivery unit flange.

   
Installation position of fuel delivery unit flange
Marking on sender must align with the marking on fuel tank -arrows-.
Return line -1- (blue or with blue marking) 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.
  A20-0096
Checking breather valve
Valve in rest position: closed
Valve pushed in direction of arrow: open
  N20-0073
Checking pressure retention valve
From gravity valve the pressure retention valve is open in both directions of flow -arrow 1-.
From junction between activated charcoal canister/solenoid valve 1 for activated charcoal filter system, it is only open in one direction of flow -arrow 2-.
  N20-0066
Fuel pump relay -J17- - relay position 21 -
Relay is located on lower multifunctional unit relay holder.
  Note
t  If tools are necessary to pull relays or control units out of the relay plate, first disconnect battery earth strap
t  Before disconnecting battery earth strap obtain code for radios with anti-theft coding.
  N01-0486

Safety precautions when working on fuel supply system > < Removing and installing fuel tank with attachments and fuel filter: engine code AJH