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

• Read the safety precautions before starting. Refer to => [ Safety Precautions ] Safety Precautions.

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

- If necessary, take out the adapter for the wheel lock from the luggage compartment.

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

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

- Remove the rear seat bench.

- Unclip the cover - 1 - for the fuel delivery unit. the arrow - 2 - points in the direction of travel.






- Disconnect the connector - 1 - and the lines - 2 and 3 - from the fuel delivery unit. Disconnecting the couplings, refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.






- Remove the right rear wheel housing liner..

- Disconnect the lines - 1 and 2 -.






- Remove the fuel filler tube to body bolts - arrows -.

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






- Remove the exhaust system.


The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Before loosening the fuel lines, place a cloth around the connection point. Remove the hose connection carefully to release the pressure.

- Disconnect the white vent line - 1 -, the black supply line - 2 - and the green vacuum line for leak detection pump (V144) - 3 - at the separating point. Disconnecting the couplings, refer to => [ Coupling, Disconnecting ] Coupling, Disconnecting.






• A second technician is required for the rest of this procedure to help support the fuel tank.

- Remove the tensioning strap bolts - arrows -.






- Remove the fuel tank bolts - arrows - at the sides.

Installing

Install in reverse order of removal. Note the following:

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

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

• Make sure the line connections are securely fastened.

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

• Make sure the lines are still attached to the fuel tank after installing the fuel tank.

- Bleed the fuel system.

- Connect the battery.

Tightening Specifications