Fuel Tank, Fuel Filler and Attachments, Removing and Installing

Fuel tank, fuel filler and attachments, removing and installing
1. Sealing cap
2. Seal
^ Replace if damaged
3. Securing bolt
4. Tank flap unit
^ With rubber cup
5. Breather line
^ Black
^ Check seated securely
^ Clipped onto top of fuel tank
6. Ground connection
^ Check seated securely
7. Breather line
8. Gravity valve
^ To remove valve unclip upward out of support
^ Check valve for through flow
^ Valve vertical: Open
^ Valve tilted 45°: Closed
9. Seal
^ Replace if damaged
10. Change-over valve
^ To remove valve unclip sideways out of socket
^ Before installing remove sealing cap item 1
^ Checking, Refer to Fig. 2
11. Breather line
12. Pressure retention valve
^ Checking, Refer to Fig. 3
13. Breather line
^ Black
^ Check for secure seating
14. Fuel tank
15. Clamping washer
16. Heat shield
^ For fuel tank
17. 25 Nm
18. Clamping nut, 2 Nm
19. Fuel tank cover
20. Securing strap
^ Note differing lengths
^ Installation position: Fixing point (holes) point in direction of travel (forward)
21. Supply line
^ Black
^ Check for secure seating
^ To pull off of fuel filter press release buttons on connecting piece
22. Fuel filter
^ Installation position: Arrow points in direction of flow
23. Screw-type clip
^ Observe installation position
24. Breather line
^ White
^ Check for secure seating
^ Clipped onto side of fuel tank
^ To EVAP canister purge regulator valve -N80
25. Seal
^ Replace if damaged
^ When installing, insert seal dry into fuel tank opening
^ Moisten with fuel only when installing fuel delivery unit flange
26. Fuel delivery unit
^ Observe installation position of flange on fuel tank, Refer to Fig. 1
28. Supply line
^ Black
^ Check for secure seating
^ Clipped onto side of fuel tank
^ When puling off flange and fuel filter press release button on connecting piece
29. Return line
^ Blue or with blue marking
^ Clipped onto side of fuel tank
^ Check for secure seating
^ To remove from flange press release button on connecting piece
^ From fuel return pipe on fuel rail
30. Connector
^ Black, 4-pin
^ For Fuel gauge sender -G- and Fuel Pump (FP) -G6
31. 10 Nm





Fig. 1 Installation position of fuel delivery unit flange
Marking on sender must align with marking on fuel tank -arrows-.
Blue or blue marked return line -1- to union with identification -R-.
Black supply line -2- to union with identification -V-.

Note: After installing fuel delivery unit flange, check that the supply, return and breather lines are still clipped onto the fuel tank.





Fig. 2 Checking change-over valve
Lever in rest position: Closed
Lever pushed in direction of arrow: Open

Note: Before installing breather valve, remove cap from fuel tank.





Fig. 3 Checking pressure retention valve
- Check direction of valve flow:
A) Union 1-1:
^ Flow in both directions
^ Union -2- is closed
B) Union 1.2:
^ Flow in both directions
^ Union -3- is closed
C) Union 1-2:
^ Flow in only one direction
^ Union -3- is closed
^ Valve must close when a vacuum is applied to union -1





Fig. 4 Installation position of screw-type clip for fuel filter

Note: The fuel filter is illustrated viewed from the front.

- Install screw-type clip -arrow- as shown in illustration.
Make sure sufficient clearance between clip fastener and fuel tank. Dimension "a" must be at least 5 mm.