Fuel Tank

Fuel Tank

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Engine/Transmission Jack (V.A.G 1383 A)

CAUTION!
• Observe safety precautions when working on fuel supply. Refer to--> [ Fuel Supply System, Safety Precautions ] Fuel Supply System, Safety Precautions.

• Observe rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.

Always follow these instructions before and during work.

Fuel Tank, Removing

Conditions

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

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

Procedure

CAUTION!
Electronic components could be destroyed when the batter is disconnected. Follow the required steps when disconnecting the battery!

- With ignition switched off, disconnect ground cable - arrow - to the battery.





- Clean surrounding area around fuel filler tube.

- Open fuel tank flap and remove fuel tank cap.

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

- Remove right rear wheel housing liner.

- Remove fuel filler neck bolts - 1 -.





- Disconnect ABS speed sensor electrical wire - 2 - to the fuel filler neck bracket.

- Remove seat bench.

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





- Remove connector - 1 - from fuel filler unit flange.





- Remove front muffler. Refer to --> [ Muffler Assembly Overview ] Muffler Assembly Overview.

• The front and rear mufflers may have to be separated first. Refer to --> [ Front and Rear Mufflers, Separating and Connecting ] Front and Rear Mufflers, Separating and Connecting.

CAUTION!
• The fuel supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin.

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

- Disconnect black supply line - 1 - and blue return line - 2 - between fuel tank and body.





• Press in securing ring to disengage the fuel lines.

- Seal lines so that the fuel system is not contaminated by dirt etc.

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

- Remove securing strap and bolts - arrows -. Support fuel tank using engine/transmission jack (V.A.G 1383 A) while doing so





- Slowly lower fuel tank.

• The fuel filler neck must be "guided out" between the body and rear axle. To do so, lift the fuel tank down from the engine and transmission jack (V.A.G 1383 A) with the help of a second technician.

Fuel Tank, Installing

- With the help of a second technician, guide the fuel filler neck in between the rear axle and body. Then place fuel tank on to engine and transmission jack (V.A.G 1383 A).

- Lift fuel tank slowly up to the installation position and secure it with new bolts - arrows -.





• Tightening specifications --> [ 7 Mounting Bolt, 25 Nm ] Fuel Tank Assembly Overview.

Further installation is in reverse order. When doing this note the following:

• Tightening specifications, refer to --> [ Fuel Tank Assembly Overview ] Fuel Tank Assembly Overview.

• Route fuel lines kink-free.

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

• Make sure lines connections are securely fastened.

• Check the fuel tank/body ground connection on the filler neck to make sure it is seated securely --> [ 3 Ground Connection ] Fuel Tank Assembly Overview.

• After checking the installation of the fuel tank, make sure the fuel lines are still clipped onto the tank.

- Observe the notes after connecting the battery.