Fuel Tank Removal and Installation

Fuel tank, removing and installing

Special tools and equipment



- VAG 1383A engine/transmission jack
- VAG 1331 torque wrench (5 - 50 Nm)

Removing
- Note safety precautions before starting work. Service Precautions
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.

Vehicles with all wheel drive
- Remove center and rear mufflers of exhaust system
- Remove rear axle

Continued for all vehicles
- Open fuel flap.
- Remove rear right wheel housing liner: Repair Manual, Body Exterior, Repair Group 66; Removing and installing wheel housing liner

Vehicles with all wheel drive
- Remove protective plate for filler neck.

Continued for all vehicles
- Drain fuel tank and clean fuel filler neck and surrounding area.
- Unscrew securing bolts and remove tank flap unit with rubber cup.
- Remove securing bolts on filler neck.

Vehicles with all wheel drive



- Pull supply hose -1- off inlet to fuel filter.

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.

- Mark return hose -2- and breather hose -3- and separate at connecting point.
- Remove left and right protective plates on fuel tank and floor.

Vehicles with front wheel drive



- Pull supply hose -1- off fuel filter.

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.

- Mark return hose -2- and breather hose -3- and separate at connecting point.

Continued for all vehicles
- Remove tensioning strap. When doing this support fuel tank with engine/ transmission jack VAG 1383 A.



- Lower using engine/ transmission jack VAG 1383 A but only sufficiently to allow connector to be pulled off flange -arrow-.
- Lower fuel tank.

Installing
Installation is carried out in the reverse order, when doing this note the following:
- Breather and fuel hoses are to be installed kink- free.
- Make sure fuel hoses are seated securely.
- Secure fuel hoses with spring- type clamps.
- Do not interchange supply and return hose (return hose: blue or blue markings, supply hose: black).

Note: After installing fuel gauge sender, check that the supply, return and breather lines are still clipped onto the fuel tank.