Assembly overview - fuel tank

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1 Assembly overview - fuel tank vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 1 of 2 Assembly overview - fuel tank 1 - Fuel tank 2 - Sleeve When removing, support using engine and gearbox jack -V.A.G 1383 A- Removing and installing Chapter. Empty fuel tank using fuel extractor -VAS Earth connection 4 - Seal Check for secure seating. Renew if damaged. Moisten with fuel when installing. 5 - Fuel pump -G6- with fuel gauge sender -G- installation position on fuel tank Fig.. To remove, first remove fuel tank Chapter. Removing and installing fuel gauge sender Chapter. 6 - Union nut, 80 Nm Remove and install using union nut tool Supply line To fuel filter Chapter or Chapter Clipped onto fuel tank. Black To pull off flange, press release button on connecting piece. 8 - Return line From fuel cooler. Blue or with blue marking.

2 Assembly overview - fuel tank vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 2 of 2 Clipped onto fuel tank. To pull off flange, press release button on connecting piece Nm 10 - Rubber cup 11 - Securing bolt 12 - Cap Renew seal if damaged Nm 14 - Securing strap installation position Return line From fuel filter Chapter or tandem pump Blue or brown To pull off flange, press release button on connecting piece Fuel cooler Not for vehicles without fuel preheating 17 - Return line Blue or brown To pull off flange, press release button on connecting piece Wiring harness Installation position of fuel gauge sender Mark on sender flange must align with mark on fuel tank -arrows-. Connections for blue or blue-marked return line -1- and black supply line -2- are marked with an arrow on fuel gauge sender flange. After installing fuel gauge sender, check whether fuel supply and return lines are still clipped onto fuel tank.

3 Assembly overview - fuel filter, vehicles with fuel preheating vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 1 of 2 Assembly overview - fuel filter, vehicles with fuel preheating The fuel system must be bled after renewing the fuel filter. Chapter 1 - Securing clip 2 - Return line To fuel cooler 3 - Supply Blue or with blue marking. Union with marking -RT-. Check for secure seating. To pull off, press release button on connection. From fuel tank. Black 4-25 Nm Union with marking -VF-. Check for secure seating. 5 - Bracket 6-25 Nm To pull off, press release button on connection. For fuel filter. 7 - Fuel filter 8 - Seal Observe change intervals. installation position. Renew. 9 - Water drainage connection, 5 Nm

4 Assembly overview - fuel filter, vehicles with fuel preheating vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 2 of 2 To drain water connect hand vacuum pump -V.A.G and water drainage container - V.A.G 1390/1- and extract approx. 100 cm 3 of fluid Supply line To tandem pump. Union with marking -VM-. To pull off, press release button on connection Return line From tandem pump. Union with marking -RF-. To pull off, press release button on connection.

5 Assembly overview - fuel filter, vehicles without fuel preheating vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 1 of 1 Assembly overview - fuel filter, vehicles without fuel preheating The fuel system must be bled after renewing the fuel filter. Chapter 1 - Supply line 2 - Supply To tandem pump. Union with marking - VM-. Check for secure seating. To pull off, press release button on connection. From fuel tank Black Union with marking -VF-. Check for secure seating. To pull off, press release button on connection. 3 - Fuel filter Observe change intervals 4 - Bracket 5-9 Nm 6-18 Nm 7 - Bracket 8 - Bracket installation position. For fuel filter For fuel hoses

6 Safety precautions when working on fuel supply system Page 1 of 1 Safety precautions when working on fuel supply system WARNING When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: Route all the various lines (e.g. for fuel, hydraulics, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original positions. Ensure that there is sufficient clearance to all moving or hot components. When removing and installing the fuel pump and fuel gauge sender from a full or partly filled fuel tank the following must be observed: Before beginning work, place an extraction hose close to sender opening in fuel tank to extract escaping fuel fumes and switch on exhaust extraction system. If no exhaust extraction system is available, a radial fan with a displacement greater than 15 m 3 /h can be used providing that motor is not in air flow. Prevent skin contact with fuel! Wear fuel-resistant gloves! vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

7 Rules for cleanliness Page 1 of 1 Rules for cleanliness When working on the fuel supply and injection systems, pay careful attention to the following 6 rules for cleanliness: Thoroughly clean all unions and adjacent areas before disconnecting. Place removed parts on a clean surface and cover. Do not use fluffy cloths! Carefully cover opened components or seal if repairs cannot be carried out immediately. Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.). When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely necessary. Also ensure that no diesel fuel comes into contact with the coolant hoses. Should this occur, the hoses must be cleaned immediately. Damaged hoses must be renewed. vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

8 Removing and installing fuel tank with attachments Page 1 of 3 Removing and installing fuel tank with attachments Removing Special tools and workshop equipment required Union nut tool Torque wrench -V.A.G ( Nm) Torque wrench -V.A.G ( Nm) Engine and gearbox jack -V.A.G 1383 A- Fuel extractor -VAS Fuel tank must be drained. To do this, use fuel extractor - VAS safety precautions before starting work Chapter. Observe rules for cleanliness Chapter vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

9 Removing and installing fuel tank with attachments vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 2 of 3 Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted. Obtain radio code first if necessary. Open fuel flap and remove fuel tank cap. Drain fuel tank using fuel extractor -VAS and clean fuel filler neck and surrounding area. Remove securing bolt, then pull rubber cup off filler neck and remove. Remove filler neck securing bolt. Remove lower cover with heat shield -A-. Pull fuel supply line -1- and return line -2- off fuel cooler (on vehicles fitted with auxiliary heating, disconnect additional fuel line). To do this, press buttons on hose couplings. Remove fuel cooler securing bolts and remove fuel cooler. Remove tensioning straps. When doing this, support fuel tank with engine and gearbox jack -V.A.G 1383A-. Lower engine and gearbox jack - V.A.G 1383A- just enough to allow connector to be pulled off fuel pump flange. Pull connector off fuel pump flange and unclip line from fuel tank. Lower fuel tank. Installing Installation is carried out in the reverse order. When installing, note the following:

10 Removing and installing fuel tank with attachments Page 3 of 3 Connections for breather and fuel lines must engage audibly when joined. Clip fuel lines onto fuel tank. Push connector to fuel pump flange and clip line onto fuel tank. Ensure that fuel hoses are tight. vw-wi://rl/n.en-gb.k wi:: xml?xsl=3

11 Removing and installing fuel gauge senderg vw-wi://rl/n.en-gb.k wi:: xml?xsl=3 Page 1 of 1 Removing and installing fuel gauge sender -G- Removing Remove fuel tank Chapter. Remove fuel pump -G6-. Release connector lugs on lines -3- and -4- and pull off. Raise retaining tabs -1- and -2- using a screwdriver and pull fuel gauge sender -Goff downwards -arrows-. Installing Insert fuel gauge sender -G- into guides on fuel pump -G6- and press upwards until it engages.

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