Fuel Tank, Removal and Installation

Fuel tank, removing and installing

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





^ VAG1383A Engine/transmission jack





^ VAG1331 Torque wrench (5...50 Nm)

Removing

Note:
^ Observe safety precautions before starting work.
^ Fuel extraction unit VAS5190 is recommended to empty the fuel tank.

^ Check whether a coded radio is installed. If so, obtain anti-theft coding.
^ With ignition switched off disconnect battery Ground strap.
^ Open fuel flap.
^ Remove rear axle:
^ Remove right rear wheelhousing liner:





^ Remove cover for fuel tank (arrows).
^ Drain fuel tank, clean fuel filler neck and surrounding area.
^ Disconnect breather lines/hoses on filler neck.
^ Remove mounting screw and remove tank flap unit with rubber cup.
^ Pull EVAP canister breather lines off.
^ Unhook gravity valve.
^ Remove securing bolt on filler neck.
^ Fold rear seat bench forward.

WARNING: Fuel supply lines are under pressure! Before removing a hose connection wrap a cloth around the connection. Then release pressure by carefully pulling the hose off the connection.

^ Remove cover from under fuel tank.
^ Remove cover from fuel delivery unit.





^ Remove 4-pin connector from flange (arrow).

WARNING: Fuel supply lines are under pressure! Before removing a hose connection wrap a cloth around the connection. Then release pressure by carefully pulling the hose off the 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 release.

^ Seal lines to avoid contamination of fuel system.
^ Remove tensioning strap. When doing this support fuel tank with engine/transmission jack VAG1383A.
^ Lower fuel tank. Guide breather hoses/lines through longitudinal member while lowering tank.

Installing
Install in reverse sequence. Note the following points:
^ Route breather and fuel hoses kink free.
^ Ensure tight fit of fuel hoses.
^ Guide breather hoses/lines through opening in longitudinal member (install line guide).
^ Secure breather hoses/lines to filler neck with spring-type clamp.
^ Do not interchange supply and return hoses (return hose blue or blue markings, supply hose black).

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

^ Adapt (match) engine control module to throttle valve control module
^ If fault memory has been erased or engine control module was disconnected from permanent positive, adapt respective components to engine control module.