Fuel Tank, Removing and Installing

Fuel Tank, Removing and Installing

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required







- V.A.G 1383 A Engine/gearbox jack







- V.A.G 1331 Torque wrench (5 to 50 Nm)

Removing
- Note safety precautions before starting work.
- First check whether a coded radio is installed. If this is the case obtain the anti-theft coding.
- With the ignition switched off disconnect battery Ground strap.
- Open fuel flap.
- Remove rear right wheel housing liner:
- Remove rear axle:
- Drain fuel tank, clean fuel filler neck and surrounding area.
- Unscrew securing bolts and remove tank flap unit with rubber cup.
- Remove securing bolt on filler neck.
- Fold rear seat bench forwards.
- Remove fuel gauge sender cover plate and detach connector.
- Remove cover from under the fuel tank.


WARNING!
Fuel supply pipes are underpressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.







- Disconnect return hose -2- (blue), supply hose -1- (black) and breather hose -3- (white) at connecting point.


NOTE: Press buttons on hose couplings to do this.


- Remove tensioning strap. When doing this support fuel tank with engine/gearbox jack V.A.G 1383 A.
- Lower fuel tank.

Installing
Installation is carried out in the reverse order, when doing this note the following:
- Breather and fuel hoses are to be installed kink-free.
- Fuel hoses are to be installed kink-free.
- Make sure fuel hoses are seated securely.
- Secure fuel hoses with spring-type clamps.
- Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).


NOTE: After installing fuel gauge sender, check that the supply, return and breather pipes are still clipped onto the fuel tank.


- Perform the work sequence "Procedure after voltage supply open circuit".