Fuel Tank Overview

Fuel Tank Overview


• Observe the safety precautions when working on the fuel supply system. Refer to => [ Safety Precautions ] Fuel Supply.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

Always follow these instructions before and during work.






1 Cap

• Replace if damaged.

2 Bolt

• 1.5 Nm

3 Ground Connection

• Ensure the connection is seated securely.

4 Bolt

• 11 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 protective plate must coincide with holes on 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

• Draining, refer to => [ Fuel Tank, Draining ] Procedures.

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

• Support using the engine-/gearbox jack (V.A.G 1383 A) when removing.

10 Lock Washer

11 Heat Shield

12 Securing Strap

• Note the installed position.

13 Suspended Mount

• For the exhaust system, see - item 2 - in the => [ Muffler Overview ] Service and Repair.

14 Seal

• Replace if damaged.

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

• Lubricate with fuel only when installing the flange.

15 Fuel Delivery Unit

• Note the installed position of the fuel delivery unit flange. Refer to => [ Installed Position, Fuel Delivery Unit Flange ].

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

• With the fuel level sensor.

• Fuel level sensor removing and installing. Refer to => [ Fuel Level Sensor G ] Service and Repair.

• With the transfer fuel pump.

• Checking the transfer fuel pump. Refer to => [ Transfer Fuel Pump G6, Checking ] Transfer Fuel Pump G6, Checking.

16 Lock Ring

• 110 Nm

• Ensure the ring is seated securely.

• Use wrench (T10202) to remove and install.

17 Fuel Supply Line

• Black or with a black mark.

• Clipped to the side of the fuel tank.

• Ensure the line is seated securely.

• To disconnect, press the release button on the connection piece.

• To the fuel filter, see - item - in the => [ Fuel Filter Overview ] Fuel Filter Overview.

18 Fuel Return Line

• Blue or with a blue mark.

• Clipped to the side of the fuel tank.

• Ensure the line is seated securely.

• To disconnect, press the release button on the connection piece.

• From the fuel filter, see - item 3 - in the => [ Fuel Filter Overview ] Fuel Filter Overview.

19 Fuel Filler Door Unit

• With a rubber gasket.

20 Ventilation

Installed Position, Fuel Delivery Unit Flange





The mark - 3 - on the flange points in the opposite direction of travel.

1. Fuel return line (blue or with a blue mark)

2. Fuel supply line (black or with a black mark)


• The fuel delivery unit flange can only be installed in this position.

• After installing the fuel delivery unit flange, make sure the supply and return lines are still clipped to the fuel tank.