Fuel Supply Line: Service and Repair
WM 203819 Removing and installing fuel supply line
Tools
Technical values
Preliminary work
1. Remove engine. -> 100119 Removing and installing engine - section on "Removing" 100119 Removing and installing engine
2. Remove rear cardan shaft. -> 393519 Removing and installing rear cardan shaft - section on "Removing" 393519 Removing and installing rear cardan shaft
3. Remove rear right wheel housing liner. -> 536919 Removing and installing rear wheel housing liner - section on "Removing" Service and Repair
4. Detach carbon canister with degassing tank and filler neck.
-> 202519 Removing and installing carbon canister - section on "Removing" Service and Repair
-> 201019 Removing and installing fuel tank - section on "Removing" Removal and Replacement
5. Open the filler flap.
6. Remove rear seat. -> 724819 Removing and installing rear seat - section on "Removing" 724819 Removing and installing 1/3-split folding rear seat 724819 Removing and installing 2/3-split folding rear seat
Removing fuel supply line
WARNING
Toxic substances
- Danger of poisoning or suffocation
-> Ventilate the work area well.
-> Never ingest or inhale.
-> Read specific information on the Hazard Sheet.
-> Wear personal protective gear.
WARNING
Highly inflammable or explosive materials
- Danger of fire or explosion
-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.
Information
- The description applies to all engine types.
- The setup and procedures required may differ slightly from the illustrations or procedures described due to engine-specific differences.
Component overview and line routing:
Fuel line routing on the underbody
1. Remove lids for the two fuel tank flanges.
1.1. To do this, cut out the carpeted floor at the perforation using a carpet knife and fold it over.
1.2. Then unscrew the M6 fastening nuts -arrows- and remove the lids.
Fastening nuts on caps
2. Disconnect the fuel pressure line (supply) -1- at the flange.
2.1. Press the two release buttons at the same time and pull the rapid-action coupling up and off.
Fuel supply and connection points without auxiliary heating
Tank flange with connection for auxiliary heating -2-
3. Disconnect fuel lines at the connection points in the engine compartment.
3.1. Pull off plastic cover -1-.
3.2. Loosen the screw-in sleeve (width across flats 17) on the pressure line -2- and counter at the hexagon (width across flats 19) on the connecting line at the same time.
3.3. Disconnect line for tank ventilation -3-.
3.4. Pull off the line for the leakage diagnosis pump if necessary -4-.
3.5. Open the line bracket at the bulkhead.
Fuel line connection points in engine compartment
4. Remove heat shields -1-.
4.1. Unscrew three M6 collar nuts -3- and one M6 screw -1- and remove the heat shields.
Heat shields on underbody (bulkhead area)
5. Remove heat shield -1- on cardan shaft.
5.1. Unscrew two M6 screws -2- and one M8 collar nut -3- and remove the heat shield.
Heat shield on cardan shaft
6. Lower the fuel tank.
6.1. Place a transmission jack (e.g. transmission jack V.A.G 1383 A WE 1082 ) in position to support and secure the fuel tank.
6.2. Unscrew fastening screws for the restraining straps and carefully lower the fuel tank.
7. Open all line brackets on the underbody and remove the wire harness.
Installing fuel supply line
Information
- The description applies to all engine types.
- The setup and procedures required may differ slightly from the illustrations or procedures described due to engine-specific differences.
1. The fuel supply line is installed in reverse order to removal.
2. Tighten fastening screws on restraining straps to => Tightening torque: 23 Nm (17 ftlb.).
3. Tighten three M6 collar nuts to => Tightening torque: 10 Nm (7.5 ftlb.) and one M6 fastening screw to => Tightening torque: 10 Nm (7.5 ftlb.).
4. Tighten two fastening screws for the heat shield on the cardan shaft to => Tightening torque: 10 Nm (7.5 ftlb.) and one collar nut for the heat shield on the cardan shaft to => Tightening torque: 20 Nm (15 ftlb.).
Subsequent work
1. Install rear seat. -> 724819 Removing and installing rear seat - section on "Installing" 724819 Removing and installing 1/3-split folding rear seat 724819 Removing and installing 2/3-split folding rear seat
2. Secure carbon canister with degassing tank and filler neck.
-> 202519 Removing and installing carbon canister - section on "Installing" Service and Repair
-> 201019 Removing and installing fuel tank - section on "Installing" Removal and Replacement
3. Close the filler flap.
4. Install rear right wheel housing liner.
-> 536919 Removing and installing rear wheel housing liner Service and Repair.
5. Install rear cardan shaft. -> 393519 Removing and installing rear cardan shaft - section on "Installing" 393519 Removing and installing rear cardan shaft
6. Install engine. -> 100119 Removing and installing engine - section on "Installing" 100119 Removing and installing engine