Fuel Tank and Components Assembly Overview

Fuel Tank and Components Assembly Overview





1 Bolt, 1.5 Nm

2 Ground Connection

• Ensure the connection is securely seated.

3 Vacuum Line

• To the Leak Detection Pump (LDP).

4 Bolt, 10 Nm

5 Rivet

6 Protective Plate

• Riveted to the lower clamp at the factory.

• When replacing the fuel tank, set the protective plate on the filler tube and rivet clamp (holes on the protective plate must align with the holes on the filler tube).

7 Wiring Router

• For the Anti-lock Brake System (ABS) wire.

• Clipped onto the protective plate.

8 Bolt, 25 Nm

• Always replace.

9 Fuel Tank

• Removing and installing, refer to => [ Fuel Tank ] Fuel Tank.

10 Lock Washer

11 Bracket for Exhaust System

12 Mounting Strap

• Note the installed position.

13 Heat Shield

14 Supply Line

• To the fuel rail.

• Ensure the line is securely seated.

15 Fuel Filter

• Installed position: Arrow points in direction of flow.

• Fuel filter assembly overview. Refer to => [ Fuel Filter Assembly Overview ] Fuel Filter Assembly Overview.

• Removing and installing, refer to => [ Fuel Filter ] Fuel Filter.

16 Vacuum Line

• From the LDP to the intake manifold.

• Clipped onto the fuel tank.

• Ensure the line is securely seated.

17 Vent Line

• From the Evaporative Emission (EVAP) canister to EVAP canister purge regulator valve.

• Clipped onto the fuel tank.

• Ensure the line is securely seated.

18 Seal

• Always replace.

• To install, place into the opening of the fuel tank dry.

• Only lubricate the inner part with fuel when installing the fuel delivery unit.

19 Fuel Delivery Unit

• Removing and installing, refer to => [ Fuel Delivery Unit ] Fuel Delivery Unit.

• Note the installed position in the fuel tank. Refer to => [ Fuel Delivery Unit Installed Position ].

• If the fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump. Refer to => vehicle diagnosis, testing and information system (VAS 5051) or vehicle diagnosis and service system (VAS 5052).

• Fuel pump, checking. Refer to => [ Fuel Pump, Checking ] Fuel Pump, Checking.

• Note the installed position on the fuel tank. Refer to => [ Fuel Delivery Unit Installed Position ].

• With fuel level sensor.

• Fuel level sensor removing and installing. Refer to => [ Fuel Level Sensor ] Removal and Replacement.

• Clean the strainer if contaminated.

20 Locking Ring, 110 Nm

• Ensure the ring is securely seated.

• Use the wrench (T10202) for removal and installation.

21 Return Line

• Blue

• Clipped onto the side of the fuel tank.

• Ensure the line is securely seated.

22 Cap

• Replace gaskets if damaged.

23 Fuel Filler Door Unit

• With a rubber gasket.

• Removing and installing.

24 To Evaporative Emission (EVAP) canister

25 Supply Line

• Black

• Clipped onto the side of the fuel tank.

• Ensure the line is securely seated.

Fuel Delivery Unit Installed Position





• The tab - 2 - on the fuel delivery unit must lie between the tabs - 1 and 3 -.

• - Arrow - points in direction of vehicle travel.

• Fuel delivery unit can only be installed in this position.