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.

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

- Drain the fuel tank using the fuel extracting device (VAS 5190) as necessary. 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 right rear wheel.

- Remove the right rear wheel housing liner..

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






- Disconnect the hoses - 1 and 2 -.

- Remove the fuel filler tube - arrows -.

- Unclip the electrical wire from the filler connection.

- Remove the center and rear mufflers.

- Remove the heat shield from the center and rear mufflers.


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

• Press the lock ring to release the lines.

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






• The green leak detection pump vacuum line must also be disconnected.

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






- Lower the fuel tank.

Installing

Install in the reverse order of removal. Note the following:

Tightening specifications, refer to => [ Fuel Tank and Attachments Overview ] Fuel Tank and Attachments Overview.

• 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 return line is blue or with a blue mark, the supply line is black).

• Pull on the line connections to make sure they are secure.

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