Fuel Tank, Removing and Installing

Fuel Tank, Removing And Installing

Special tools, testers and auxiliary items required







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







- Torque wrench (5 to 50 Nm) V.A.G 1331
- Plug tool for additive tank T10249 (engine code BGW only)

Removing

NOTE:
- The fuel tank must not be more than 1/4 full.
- Empty fuel tank using fuel siphoning unit VAS 5190.
- Observe safety precautions before performing repair work.

- Check whether a coded radio is installed. If necessary, obtain anti-theft coding.
- Disconnect battery Ground (GND) strap with ignition switched off.
- Remove wheelhousing liner, right rear: Body Exterior -.
- Unscrew securing bolts and remove tank flap unit with rubber cup.
- Remove securing bolt on filler neck.

CAUTION: During all repair procedures be aware of the following:
- Route all the various lines (e.g. fuel lines, as well as electrical wiring) so that the original positions are restored.
- Ensure sufficient clearance to all moving or hot components.
- Always perform repair procedures on open systems in rooms with adequate ventilation only.

- Remove tensioning strap while supporting fuel tank with engine/transmission jack V.A.G 1383/A.

CAUTION:
- The fuel or fuel lines in fuel system can become very hot (danger of scalding).
- In addition, the fuel system is under pressure. Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection.
- Wear protective goggles and protective gloves when working on the fuel system.

- Lower engine/transmission jack V.A.G 1383/A only so far until supply and return lines and connector on fuel level sensor can be disconnected.

NOTE: Press in securing ring to disengage the fuel lines.

- Unclip supply and return lines at fuel tank and separate connector for fuel level sensor.
- Lower fuel tank.

Installing
Installation is performed in reverse order. When doing this note the following:
- Route the vent hoses kink-free.
- Route the fuel hoses kink-free.
- Secure fuel lines with clamps.
- Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).
- Clip in the supply and return lines at fuel tank.