Fuel Tank, Removing and Installing

WARNING!
Fire hazard! Do NOT have anything in the area that can ignite gasoline!






Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
- VAG 1383 A Engine/transmission jack







- VAG 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft lb)

Fuel tank, removing
- Note safety precautions before starting work
- Open fuel flap.


CAUTION!
Obtain radio anti-theft code from customer BEFORE disconnecting battery Ground strap!


- With ignition switched OFF disconnect battery Ground.
- Remove rear axle
- Remove right, rear wheel housing liner







- Remove covers under fuel reservoir
- Drain fuel tank, clean fuel filler neck and surrounding area.
- Disconnect vent lines at fuel filler neck
- Remove vent lines from EVAP canister
- Disconnect gravity valve / expansion valve
- Remove filler neck mounting bolts.
- Fold rear seat bench forwards.
- Remove the fuel gauge sensor cover plate and disconnect harness connector.





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


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


NOTE: Do this by pressing on hose buttons couplings -arrows- .
- Remove tensioning strap by supporting fuel tank with VAG 1383 A engine/transmission jack.
- Lower fuel tank..


Installing
Installation is carried out in the reverse order of the removal procedure, when doing this note the following:
- Breather and fuel hoses must be installed kink-free.
- Ensure fuel hoses are seated securely.
- Guide vent lines through the opening in the long member (install wire routing).
- Secure vent lined on filler neck with spring clamp.
- Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).


NOTE: After installing fuel gauge sensor, ensure that the supply return and breather lines are still clipped onto the fuel tank.

- Check DTC (Diagnostic Trouble Code) memory
Refer to "On Board Dignostics II". Testing and Inspection
- If malfunctions occur, display Readiness code
Refer to "On Board Dignostics II".
- Match Engine Control Module to Throttle Control Module
Refer to "On Board Dignostics II".