Fuel Tank

Fuel Tank

Special tools, testers and auxiliary items required

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

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.

• Fuel tank and attachments overview. Refer to => [ Fuel Tank and Attachments Overview ] Fuel Tank and Attachments Overview.

- Drain the fuel tank as 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 - arrow - from the flange.






- Remove the right rear wheel.

- Remove the right rear wheel housing liner..






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






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

- Remove the door unit bolt and remove the door unit.

- Remove the fuel filler tube bolt - 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.

- Disconnect the ventilation line (white) - 1 - and the fuel line (black) - 2 - at the separating point.






• Press the lock ring to unlock the lines.

- Lower the rear subframe.

• Make sure there is sufficient clearance for the brake lines and electrical wires when lowering the rear subframe.

• Have a second technician help when disconnecting and lowering the fuel tank.

- Hold the fuel tank and remove the bolts - arrows - for the straps.






- Remove the straps.

- Lower the fuel tank slowly with a second technician and guide it out from between the rear subframe and the vehicle body.

Installing

- With help from a second technician, guide the fuel filler neck between the rear subframe and chassis.

- Hold the fuel tank in its installed position and install the straps and new bolts - arrows -.






• Only use bolts with loose washers to secure the fuel tank 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 order to removal. Note the following:

• 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.

Tightening Specifications