Fuel Tank, Removing and Installing

Fuel tank, removing and installing
Special tools and equipment





^ VAG 1331 Torque wrench (5..50 Nm)





^ VAG 1383 A Engine/gearbox jack

Removing
- Observe safety precautions before starting work, Refer to Fuel Delivery and Induction, Service Precautions.
- 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
- Remove rear axle
- Drain fuel tank, clean fuel filler neck and surrounding area.
- Unscrew mounting screw and remove tank flap unit with rubber cup.
- Remove securing screws on filler neck.
- Fold rear seat bench forward.
- Remove cover from fuel delivery unit.





- Remove 4-pin connector from flange -arrow-.





- Remove cover for fuel tank -arrows-.





- Disconnect return line -2- (blue), supply line -1- (black) and breather line -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 connections 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 VAG 1383 A.
- Lower fuel tank.

Installing
Install in reverse sequence; note the following points:
^ Route breather and fuel hoses kink free.
^ Make sure tight fit of fuel hoses.
^ 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 pipes are still clipped onto the fuel tank.

- Check DTC memory:
Refer to Powertrain Management
- Adapt (match) engine control module to throttle valve control module:
- Perform work sequence "Procedure after interrupting voltage supply":
- Read readiness code:
Refer to Powertrain Management
- Generate readiness code again if DTC memory has been erased or engine control module separated from permanent positive supply: