Fuel Tank

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

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

- 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 connector - arrow -.






- Remove the bolt for the fuel filler door unit and remove the door unit.

- Remove the tension struts - A and B -.






- Remove the center and rear mufflers.

- Remove the center muffler heat shield.

- Remove the right rear wheel.

- Remove the rear right wheel housing liner.

- Unclip the electrical wire - 1 - from the filler tube connection.






- Disconnect the ventilation line - 3 -.

- Remove the fuel filler tube bolts - 2 - from the body.

- Press the lock rings in and disconnect the vent line - 1 - (white) behind the fuel tank.






- Press the lock ring in and disconnect the vacuum line - 2 - (green) for the leak detection pump behind the fuel tank.

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. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

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






• Press the lock rings to release the lines.

• Also disconnect the leak detection pump vacuum line (green).

- Remove the strap bolts - arrows - and straps. Support the fuel tank using the engine-gearbox jack (V.A.G 1383 A) while doing so






- Carefully lower the fuel tank.

Installing

Install in the reverse order of removal. 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 confuse the supply line and the return line (the return line is blue and the supply line is black).

• Make sure the line connections are securely fastened.

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

- Install the tension struts.

Tightening Specifications






1 always replace