Fuel Tank

Fuel Tank

Special tools, testers and auxiliary items required

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

Removing

• The fuel tank may be a maximum of 1/4 full.

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

• 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.

- Turn off the ignition and all electric consumers and remove the key.

- Open the fuel filler flap and remove the fuel filler cap.

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

- Remove the rear bench seat.

- Remove the cover - 1 - from the fuel delivery unit. The arrow - 2 - points in the direction of travel.






- Disconnect the connector - arrow - from the fuel delivery unit.






- Remove the right rear wheel housing liner.

- Disconnect the connectors - 1 and 2 -.






- Remove the fuel filler pipe bolts - arrows -.

- Unclip the Antilock Brake System (ABS) line - A - from the bracket - arrows -.






- Remove the center muffler. It may be necessary to separate the center and rear mufflers beforehand. Refer to => [ Middle and Rear Mufflers, Separating and Connecting ] Middle and Rear Mufflers, Separating and Connecting.


The fuel system is under pressure!

• Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.

• Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

- Disconnect the ventilation line from the Evaporative Emission (EVAP) canister at the connection behind the fuel tank.

- Disconnect the white vent line - 1 -, black supply line - 2 - and green vacuum line for the leak detection pump (V144) - 3 - at the connecting point.






• Press in the securing rings to disengage the lines.

• For the continuing work sequence, a second mechanic is needed to support the fuel tank.

- Remove the tensioning strap bolts, the tank side bolts - arrows -, and the straps.






- Remove the fuel tank.

Installing

Installation is performed in the reverse order of removal. When doing this note the following:

• 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.

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

• Do not interchange the supply and return lines (the supply line is black, the return line is blue).

• Make sure the connector and the lines are secure. Pull on them if necessary.

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

• After installing the fuel tank, check to be sure the lines are still clipped onto the fuel tank.

- Bleed the fuel supply system. Refer to => [ Fuel System, Bleeding ] Service and Repair.

Tightening Specifications