Front Wheel Drive

Fuel Tank

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Engine-/Gearbox Jack (V.A.G 1383 A)

Removing

• The rear subframe must be lowered to remove the fuel tank.

- Read the safety precautions before starting. Refer to => [ Safety Precautions ] Fuel Supply.

- Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

Drain the fuel tank if necessary, using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

- Remove the rear seat bench.

- Remove the cover - 1 - and the fuel pump control module - 2 - from the fuel delivery unit.






- Disconnect the 5 pin connector from the flange.






- Remove the right rear wheel.

- Remove the rear right wheel housing liner..

- Disconnect the vent and vacuum lines - arrows - from the Evaporative Emission (EVAP) canister.






- Unclip the electrical wire from the filler tube - arrows -.






- Remove the bolt for the fuel flap unit and remove the fuel flap unit.

- Remove the fuel filler tube bolts - arrows -.






The fuel supply line is under pressure. Always wear protective eye wear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

• Press the locking ring to release the fuel lines.

- Disconnect white vent line, the green vacuum line and the black fuel line - A, B and C - at the connection point.






- Support the rear subframe using the engine-/gearbox jack (V.A.G 1383 A).

- Loosen the bolts - arrows - and lower the rear subframe.






- Remove the securing strap bolts - arrows -. Support the fuel tank using the engine-/gearbox jack (V.A.G 1383 A) beforehand.






- Slowly the lower fuel tank.

• The fuel filler tube must be "removed" from between the chassis and rear subframe. To do so, lift the fuel tank with help from a second mechanic, down from the engine-/gearbox jack (V.A.G 1383 A).

Installing

- With help from a second technician, guide the fuel filler neck up between the rear subframe and chassis. Then, place the fuel tank on the engine-/gearbox jack (V.A.G 1383 A).

- Lift the fuel tank slowly up it's installed position and secure it with the bolts - arrows -.






• Only use bolts with loose washers to secure the straps. The straps could twist when the bolts are tightened if other bolts are used. For the correct bolts, refer to the Parts Catalog.

- Secure the rear subframe to the chassis.

Further installation is in the reverse sequence to removal. When doing this note the following:

• For the correct tightening specifications, refer to => [ Fuel Tank and Attachments Overview ] Fuel Tank and Attachments Overview.

• Make sure the vent and fuel lines are not kinked.

• Pull on the line connections to make sure they are secure.

• Check the fuel tank to body ground connection on the filler tube.

• If the fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump. Refer to "Guided Functions" in the vehicle diagnostic tester.