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Volkswagen Golf Variant / Jetta. Manual - part 412

Overview - Fuel Tank, All Vehicles Ex‐

cept Jetta from MY 2011

DANGER!

♦ Observe safety precautions when working on fuel supply.

Refer to

⇒ “1 Safety Precautions when Working on Fuel Supply

System”, page 223

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 224

Always pay attention to these instructions before and during

work.

1 - Cap

❑ Replace if damaged

2 - Bolt

❑ 1.5 Nm

3 - Ground Connection

❑ Check for secure fit

4 - Bolt

❑ 11 Nm

5 - Bracket

❑ For the ABS speed sen‐

sor wire

6 - Fuel Tank

❑ Draining. Refer to

⇒ “4.4 Fuel Tank, Drain‐

ing”, page 235

❑ Removing and instal‐

ling. Refer to

⇒ “4.5 Fuel Tank, Re‐

moving and Installing”,

page 238

❑ Support while removing

with the Engine and

Gearbox Jack -

VAS6931- .

7 - Bolt

❑ 25 Nm
❑ Replace

8 - Heat Shield
9 - Lock Washer
10 - Mounting Strap

❑ Note the installation po‐

sition

11 - Mount

❑ For the front muffler of the exhaust system -item 2-

⇒ Item 2 (page 381)

4. Fuel Supply System Components

231

❑ Replace if damaged
❑ Insert dry into the fuel tank opening
❑ Coat with fuel only when installing the flange

13 - Fuel Delivery Unit

❑ Note the installation position of the fuel delivery unit flange. Refer to

⇒ Fig. ““Fuel Delivery Unit Flange Installation Position”“ , page 232

❑ Fuel Delivery Unit, Removing and installing. Refer to

⇒ “4.6 Fuel Delivery Unit, Removing and Installing”, page 241

❑ With the Fuel Level Sensor - G-
❑ Fuel Level Sensor - G- , Removing and installing. Refer to

⇒ “4.7 Fuel Level Sensor G , Removing and Installing”, page 243

❑ With the Transfer Fuel Pump - G6-
❑ Transfer Fuel Pump - G6- , Checking. Refer to

⇒ “6.4 Transfer Fuel Pump G6 , Checking”, page 252

14 - Locking Ring

❑ 110 Nm
❑ Check for secure fit
❑ Remove and install with the Wrench - Fuel Sending Unit - T10202- .

15 - Fuel Supply Line

❑ Black
❑ Attached to the side of the fuel tank
❑ Check for secure fit
❑ To disconnect, press the release button on the connecting piece
❑ To fuel filter -item 1-

⇒ Item 1 (page 250)

16 - Fuel Return Line

❑ Blue
❑ Attached to the side of the fuel tank
❑ Check for secure fit
❑ To disconnect, press the release button on the connecting piece
❑ From fuel filter -item 3-

⇒ Item 3 (page 250)

17 - Fuel Filler Door Unit

Unit, Removing and Installing .

Fuel Delivery Unit Flange Installation Position
The mark -3- on the flange points opposite the direction of travel.
1 - Fuel Return Line (Blue)
2 - Fuel Supply Line (Black)
3 - Marking

Note

♦

The fuel delivery unit flange can only be installed in this posi‐

tion.

♦

Make sure the supply and return lines are still clipped to the

fuel tank after the fuel delivery unit flange has been installed.

232

Overview - Fuel Tank, Jetta from MY

2011 Only

DANGER!

♦ Observe safety precautions when working on fuel supply.

Refer to

⇒ “1 Safety Precautions when Working on Fuel Supply

System”, page 223

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 224

Always pay attention to these instructions before and during

work.

1 - Cap

❑ Replace if damaged

2 - Bolt

❑ 1.5 Nm

3 - Ground Connection

❑ Check for secure fit

4 - Bolt

❑ 11 Nm

5 - Rivet
6 - Protective Plate

❑ Riveted to lower clamp

at factory

❑ When replacing fuel

tank, set protective plate

on filler tube and rivet

clamp (holes on protec‐

tive plate must coincide

with holes on filler tube).

7 - Cable Guide

❑ For the ABS line
❑ Clipped to the shield

8 - Bolt

❑ 25 Nm
❑ Replace

9 - Fuel Tank

❑ Draining. Refer to

⇒ “4.4 Fuel Tank, Drain‐

ing”, page 235

❑ Removing and instal‐

ling. Refer to

⇒ “4.5 Fuel Tank, Re‐

moving and Installing”, page 238

❑ Support while removing with the Engine and Gearbox Jack - VAS6931- .

4. Fuel Supply System Components

233

❑ Note the installation position

13 - Mount

❑ For the exhaust system -item 2-

⇒ Item 2 (page 383)

14 - Seal

❑ Replace if damaged
❑ Insert dry into the fuel tank opening
❑ Coat with fuel only when installing the flange

15 - Fuel Delivery Unit