Section D - Fuel Line Replacement

(2001-2005 1.8T Vehicles)

If not already done:
- Save all customer settings (i.e. radio stations, A/C settings)
- Switch off ignition and all electrical consumers
- Disconnect battery ground (GND) strap
- Open fuel filler cap to relieve tank pressure

WARNING:
- Fire hazard. Do not smoke or work near heaters or have anything in the area that could ignite fuel or fumes
- Fuel system is under pressure. Before opening system, place a cloth around the connection. Release pressure by carefully loosening the connection
- Always wear eye protection and wear fuel resistant gloves when disconnecting system connections
- Ensure battery is disconnected





- Remove air filter housing





- Remove and discard insulating foam -circle- located below air filter housing





- Disconnect fuel lines at fuel rail -arrows-

TIP: Before removing lines, place a cloth around connection to capture excess fuel





- Raise vehicle.
- Remove underbody cover plate -dotted line-.





- Remove fuel line clamp for supply line located at fuel filter, then disconnect line from fuel filter





- Remove fuel line clamps for vent line and return line located above fuel filter, then disconnect lines





- Remove passenger side wheel
- Disconnect EVAP line -circle- located in passenger side wheel well





- Unclip fuel lines along underbody
- Remove and discard old fuel line clips -circle-.





- Pull fuel lines through opening -circle- from engine compartment to wheel well





- Insert new fuel lines (3B0 201 544BS) into clip along underbody and gently push through opening at wheel well
- Reconnect fuel lines at fuel filter and install three new clamps (N 024 1222)
- Reconnect EVAP line and install two new clamps (N 904 119 01)





- Secure new fuel line clips in place by pushing clip onto existing stud -arrow-

NOTE:
Ensure that fuel lines are not touching together and are positioned free and clear of vehicle body





- Insert vent line from N-80 EVAP canister purge valve into fuel line retaining bracket -arrow-, then push firmly on bracket near latch to ensure it clips properly into place, and proceed to Section D