Removal and Replacement

Fuel Tank

Special tools, testers and auxiliary items required

• Torque wrench 5-50 Nm (VAG 1331)

Removing

• 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 ] Procedures.

• Read the safety precautions before beginning work. Refer to --> [ Safety Precautions ] Safety Precautions.

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

- First, check whether a coded radio is installed. If necessary, obtain the anti-theft coding.

- If necessary, remove the key for the wheel lock from the luggage compartment.

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

- Disconnect the battery..

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

- Remove the rear seat bench.

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





- Disconnect the electrical connector - 1 - from the fuel delivery unit.





- Remove the right rear wheel housing liner.

- Disconnect the connections - 1 - and - 2 - (engine codes BGP, BGQ, CBTA and CBUA only).





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

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





- Remove the front muffler, the front and rear mufflers must be separated beforehand if necessary. Refer to --> [ Middle and Rear Mufflers, Separating and Connecting ] Middle and Rear Mufflers, Separating and Connecting.

CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before loosening the fuel lines, place a cloth around the connection point. Then release pressure by carefully disconnecting the connection.

- Disconnect the white vent line - 1 -, black supply line - 2 - and green vacuum line for the Leak Detection Pump (LDP) - 3 - at the connecting points (engine codes BGP, BGQ, CBTA and CBUA only).





• Press in the securing ring to disengage the lines.

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

- Remove the tension strap bolts - arrows - and straps.





- Remove the fuel tank side bolts.

Installing

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

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

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

• Make sure the line connections are seated securely.

• Check the ground connection for the fuel tank/chassis at the filler tube.

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

- Bleed the fuel system. Refer to --> [ Fuel System, Bleeding ] Procedures.

- Connect the battery..

Tightening Specifications