Fuel Tank, Removing and Installing

Fuel Tank, Removing And Installing (Engine Codes AVH, BEV)

Special Tools And Equipment







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







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

Removing

NOTE:
- Observe safety precautions before starting work.
- The fuel extraction unit VAS 5190 is recommended for emptying 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 right rear wheelhousing liner:
- Drain fuel tank and clean fuel filter neck and surrounding area.
- Remove securing bolt on filler neck.
- Fold rear seat bench forward.
- Remove cover from under fuel tank.
- Remove rear axle:

WARNING:
- The fuel system is under pressure. Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
- Always wear eye protection and wear fuel-resistant gloves when disconnecting system connections.

- Remove cover from fuel delivery unit.







- Disconnect 4- pin connector from flange (arrow).







- Remove cover from under fuel tank (arrow)







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

NOTE: To disconnect, press buttons on hose couplings.

WARNING:
- The fuel system is under pressure. Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
- Always wear eye protection and wear fuel-resistant gloves when disconnecting system connections.

- Seal lines so that fuel system is not contaminated by dirt etc.
- Remove tensioning strap. When doing this support fuel tank with engine and transmission jack V.A.G 1383 A.
- Lower fuel tank.

Installing
Installation is performed in reverse order to removal, note the following:
- Install breather and fuel hoses free of kinks.
- Secure fuel hoses with spring-type clips
- Ensure fuel hoses are tight.

NOTE: Do not interchange supply and return hoses (return line blue or blue markings, supply line black)

NOTE: After installing the 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, Adapting components and functions.
- Generate readiness code again if DTC memory has been erased or engine control module was disconnected from permanent positive, Adapting components and functions.