Fuel tank with attachments – assembly overview and fastening

• 1 Fastener
• 2 Cap
• 3 Sealing ring
  • Renew if damaged
• 4 Securing bolt
• 5 Tank flap unit
  • With rubber cup.
  • Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55; Tank flap unit; Removing and installing fuel tank flap unit.
• 6 Gravity valve
  • To remove valve unclip upwards out of support.

Check valve for through-flow.

• Valve vertical: open.
• Valve tilted 45°: closed.

• 7 Earth connection
  • Ensure firm seating.
• 8 Breather hose
  • Ensure firm seating.
• 9 Activated charcoal filter
  • Location: in rear right wheel housing.
• 10 10 Nm
• 11 Breather hose
  • Clipped onto fuel tank.
  • Ensure firm seating.
• 12 25 Nm
• 13 Fuel tank
  • When removing, support using engine and gearbox jack - V.A.G 1383 A-.
  • Removing and installing ⇒ 1.6 Removing and installing fuel tank
  • Fuel system must be bled if fuel tank is renewed ⇒ 1.10 Bleeding fuel system.
• 14 Tensioning strap
• 15 Breather hose
  • Ensure firm seating.
• 16 Retaining clip
  • Check for firm seating
• 17 Fuel filter
  • Installation position: arrow indicates direction of flow.
  • Fuel system must be bled if fuel filter is renewed ⇒ 1.10 Bleeding fuel system.
• 18 Supply pipe
  • black
  • Ensure firm seating.
  • To fuel rail
• 19 Sealing ring
  • Renew if damaged
• 20 O-ring
  • Renew
• 21 Fuel pressure regulator

• 22 5 Nm
  • For fuel filter clamp
• 23 Sealing ring
  • Renew if damaged
  • When installing, fit dry in fuel tank opening.
  • Moisten with fuel only when installing flange.
• 24 Fuel gauge sender
  • Removing and installing ⇒ 1.5 Removing and installing fuel gauge sender
  • Adjusting ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
• 25 Fuel delivery unit
  • Removing and installing ⇒ 1.4 Removing and installing fuel delivery unit
  • Clean strainer if soiled
  • Checking fuel pump ⇒ 1.9 Checking fuel pump.
  • Note installation position on fuel tank ⇒ 1.1 Assembly overview - fuel tank with attachments
  • Fuel system must be bled if fuel delivery unit is renewed ⇒ 1.10 Bleeding fuel system.
• 26 Return line
  • blue
  • Clipped onto side of fuel tank.
  • Ensure firm seating.
• 27 Supply pipe
  • black
  • Clipped onto side of fuel tank.
  • Ensure firm seating.
• 28 Union nut, 80 Nm
  • Remove and install using union nut tool - 3217-.
• 29 10 Nm
• 30 Bleeder valve
  • Checking ⇒ 1.1 Assembly overview - fuel tank with attachments
  • To remove press locking latch lightly -arrow- and pull valve out.

Installation position of fuel delivery unit

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-.

Checking breather valve

Lever in rest position: closed

Lever pushed in direction of arrow: open