Volkswagen Workshop Service and Repair Manuals

• Cap
• Securing clip
• Seal
• ◆ Renew if damaged
• Tank flap unit
• ◆ Removing and installing

=> General body repairs, Exterior; Repair group 55; Tank flap unit

• Vent pipe

• Gravity/overflow 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
• O-ring
• ◆ Renew if damaged
• Earth connection
• ◆ Check securely seated
• 10 Nm
• Filler pipes
• ◆ With non-return valve
• Sealing boot
• ◆ After installing filler pipes fit over fuel tank connections, having turned boot inside out

• Fuel tank
• ◆ Support with engine/gearbox jack V.A.G 1383 A when removing
• ◆ Removing and installing
  
• Heat shield
• ◆ Press clamping washer from heat shield tightly onto pins on vehicle floor
• Securing strap
• ◆ Note differing length
• 25 Nm
• Fuel gauge sender
• ◆ Note fitting position on fuel tank => Fig. 1

• Sealing ring
• ◆ Renew if damaged
• ◆ Coat with fuel when installing
• Flange
• ◆ Note fitting position on fuel tank => Fig. 1
• Union nut
• ◆ Remove and install with spanner 3217
• Return pipe
• ◆ From fuel cooler
  => Page 20-14
• ◆ Blue or with blue marking
• ◆ Clipped onto fuel tank
• ◆ Check securely seated
• ◆ To remove from flange press release button on connecting piece

• Supply pipe
• ◆ To fuel filter
  => Page 20-8
• ◆ Clipped onto fuel tank
• ◆ Check securely seated
• ◆ Black
• ◆ Press release button on connecting piece to pull off flange
• Vent valve
• ◆ Checking =>Fig.2
• ◆ To remove valve unclip sideways out of support
• ◆ Before installing remove sealing cap
• Cup
• ◆ For filler pipes
• Retaining ring
• Connector
• ◆ Black, 2-pin

→ Fig. 1    Installation position of fuel gauge sender

Marking on sender must align with the marking on fuel tank -arrows-.

Connections for return flow pipe -1- (blue or with a blue mark) and black supply pipe -2- are marked on the fuel gauge sender flange by arrows.

Note:

After installing fuel gauge sender ensure that the supply pipe and return pipe are securely clipped into fuel tank.

→ Fig. 2    Checking vent valve

Lever in rest position: Closed

Lever pushed in direction of arrow: Open

Note:

Before installing vent valve remove fuel tank cap.