Fuel Tank, Removing and Installing

Fuel tank, removing and installing

Special tools and equipment





^ V.A.G. 1331 Torque wrench (5 50 Nm)





^ V.A.G. 1383 A Engine/transmission jack

Removing

Note:
^ Observe safety precautions before starting work.
^ Fuel extraction unit VAS 5190 is recommended to empty fuel tank.
^ Check whether a coded radio is installed. If so, obtain anti-theft coding.
^ With ignition switched off disconnect battery Ground strap.
^ Open fuel flap.
^ Remove rear right wheel housing liner:
^ Drain fuel tank, clean fuel filler neck and surrounding area.
^ Remove mounting screw and remove tank flap unit with rubber cup.
^ Remove securing bolt on filler neck.
^ Fold rear seat bench forward.
^ Remove cover from under fuel tank.
^ Remove rear axle:

WARNING! Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

^ Remove cover from fuel delivery unit.





^ Pull 4-pin connector off flange (arrow).





^ Remove fuel tank cover (arrows).





^ Disconnect return hose -2- (blue), supply hose -1- (black) and breather hose -3- (white) at connecting point.

Note: Press buttons on hose couplings to do so.

WARNING! Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

^ Seal lines to avoid contamination of fuel system.
^ Remove tensioning strap. When doing this support fuel tank with engine/transmission jack V.A.G. 1383A.
^ Lower fuel tank.

Installing
Install in reverse sequence noting the following points:
^ Route breather and fuel hoses kink free.
^ Ensure tight fit of fuel hoses.
^ Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).
^ After installing the fuel gauge sender, check that the supply, return and breather lines are still clipped onto the fuel tank.
^ Check Diagnostic Trouble Code (DTC) memory, repair faults if necessary and then erase DTC memory.
^ If DTC memory has been erased or engine control module was disconnected from permanent positive, respective components must be adapted to engine control module,and readiness code re-generated.
^ Road test vehicle and check all DTC memories:
Refer to Diagnostic tester VAS 5051; Guided fault finding; Vehicle system test
^ Read readiness code.