Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSVOLKSWAGEN2003PASSAT SEDAN 4MOTION (3B3) W8-4.0L (BDP)REPAIR AND DIAGNOSISACCESSORIES AND OPTIONAL EQUIPMENTTRIP COMPUTERFUEL FLOW SENSORLOCATIONSSYSTEM
2003 Volkswagen Passat Sedan 4Motion (3B3) W8-4.0L (BDP)
System
2003 Volkswagen Passat Sedan 4Motion (3B3) W8-4.0L (BDP)SECTION System
Fuel tank with assembly components, disassembling and assembling
1 Connector
- Black, 4-pin
- for Sender for fuel gauge -G-and Fuel Pump (FP)-G6-
2 Locking ring, 145 Nm
- Check for secure fitting
- Use wrench 3087 to remove and install
3 Supply line
- Black
- Check for secure fitting
- secure with spring type clamps
4 Sender for fuel gauge -G-
5 Fuel pump
- Checking Fuel Pump (FP)
- Clean strainer if dirty
6 2 Nm
7 Supply line
- Black
- Check for secure fitting
- secure with spring type clamps
- to fuel supply line at fuel distributor (cylinder bank 1), Item 1
8 Fuel filter
9 Vent line
- Check for secure fitting
- secure with spring type clamps
10 Vent line
- Check for secure fitting
- secure with spring type clamps
11 from connecting hose
12 Union nut, 60 Nm
- Use wrench 3218 to remove and install
13 Connector
- black, 2-pin
- to Sender for fuel gauge
14 Flange
- Note installation position at fuel tankFig. 1
15 Seal
- Replace if damaged
- to install, place into opening of fuel tank dry
- only coat with fuel when installing flange item 14
16 Fuel Supply Sensor 3 -G237-
17 Mounting clip
- Check for secure fitting
18 Heat shield
- for fuel tank
19 Connecting piece
- to connecting hose of auxiliary fuel tank, item 7
20 23 Nm
21 10 Nm
22 Tension strap
- Note installed position
23 Fuel Level Sensor 2 -G169-
24 Fuel tank
25 Return line
- blue or with blue marking
- Check for secure fitting
- secure with spring type clamps
- from fuel return line at fuel distributor (cylinder bank 2), Item 3
Fig. 1 Installation position of Fuel Pump (FP) flange
Marking on flange -1- must align with marking on fuel tank -2-.
NOTE: After installing Fuel Pump (FP) flange, check whether supply, return and vent lines are still clipped in at fuel tank.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.