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 V.A.G 1331

Removing

NOTE:
- Observe safety precautions before beginning work.
- The fuel extraction unit VAS 5190 or an equivalent is recommended to empty the fuel tank.

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







- Remove fuel tank covers -arrows -.
- Drain fuel tank and clean area of fuel filler neck (unscrew filler cap).
- Unscrew securing bolt and remove tank flap unit with rubber cup.
- Disconnect breather lines on filler neck.
- Disconnect breather lines connecting hoses at top of filler neck and EVAP canister.
- Remove securing bolt on filler neck.
- Fold rear seat bench forward.
- Remove cover from fuel delivery unit.







- Disconnect 4-pin connector on flange -arrow -.

CAUTION: Fuel supply lines are under pressure. Before loosening hose connections, 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 locking ring inward to release fuel lines.

- Seal lines so that fuel system is not contaminated by dirt etc.
- Remove tensioning strap. When doing this support fuel tank with engine/transmission jack V.A.G 1383 A.
- Lower fuel tank. Guide breather hoses/lines through longitudinal member.

Installing
Installation is performed in the reverse order. When installing, note the following:
- Install breather and fuel hoses free of kinks.
- Ensure fuel hoses are tight.
- Guide breather hoses/lines through opening in longitudinal member (install line guide).
- Secure breather hoses/lines to filler neck with spring-type clamps.
- Do not interchange supply and return hose (return line blue or blue markings, supply line black).

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

- Interrogate Diagnostic Trouble Code (DTC) memories of all control modules, repair faults if necessary and then erase DTC memory Vehicle diagnosis, Testing and Information system VAS 5051 ; Guided fault finding; Vehicle system test or Vehicle diagnosis, Testing and Information system VAS 5052; Vehicle self-diagnosis.
- Test drive vehicle and interrogate DTC memory of all control modules again.

NOTE: Observe applicable safety precautions during road test.