Fuel Tank, Removing and Installing
Fuel tank, removing and installing
Engines: AEG, APK AQY, AVH, AZG, BEJ, BER, BEV, BHP
Special tools and equipment
- V.A.G. 1331 Torque wrench (5 to 50 Nm)
- V.A.G. 1383 A Engine and transmission jack
Removing
Note:
^ Observe safety precautions before starting work.
^ The fuel extraction unit VAS 5190 is recommended for emptying the 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.
- Drain fuel tank and clean fuel filter neck and surrounding area.
- Remove securing bolt on filler neck.
- Fold rear seat bench forward.
- Remove cover from under fuel tank.
- Remove rear axle
WARNING:
^ The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
^ Always wear eye protection and wear fuel resistant gloves when disconnecting system connections.
- Remove cover from fuel delivery unit.
- Disconnect 4- pin connector off flange (arrow).
- Remove cover from under the fuel tank (arrow)
- Disconnect return hose -2- (blue), supply hose -1- (black) and breather hose -3- (white) at connecting point.
Note: To do this, press buttons on hose couplings.
WARNING:
^ The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
^ Always wear eye protection and wear fuel resistant gloves when disconnecting system connections.
- Seal the lines so that the fuel system is not contaminated by dirt etc.
- Remove tensioning strap. When doing this support fuel tank with engine and transmission jack V.A. G 1 383 A.
- Lower fuel tank.
Installing
Installation is performed in reverse order to removal, note the following:
^ Install breather and fuel hoses free of kinks.
^ Secure fuel hoses with spring-type clips
^ Ensure fuel hoses are tight.
^ Do not interchange supply and return hoses (return line blue or blue markings, supply line black)
Note: After installing the fuel gauge sender, check that the supply return and breather lines are still clipped onto the fuel tank.
- Adapt (match) engine control module to throttle valve control module, Refer to Adapting components and functions.
- Generate readiness code again if DTC memory has been erased or engine control module was disconnected from permanent positive, Refer to Adapting components and functions.
Engine: BBW
Special tools and equipment
- V.A.G. 1331 Torque wrench (5 to 50 Nm)
- V.A.G. 1 383 A Engine/ transmission jack
- Textile or rubber mat
Requirements
^ Fuel tank must be empty
Removing
Note:
^ Observe safety precautions before starting work .
^ The fuel extraction unit VAS 5190 is recommended for emptying the fuel tank. Contrary to the operating instructions the draining must not occur via the filler neck in this engine/vehicle or inner components will be damaged. Empty fuel tank only via the open flange.
- Open fuel flap.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Fold rear seat bench forward.
- Remove cover from fuel delivery unit.
- Disconnect 4-pin connector -1-.
- Unscrew nuts -2- and take flange -3- off.
- Drain fuel tank via flange opening, e.g. with VAS 5190.
- Bolt on flange again.
- Remove rear axle:
- Remove rear part of exhaust system.
- Remove rear right wheel housing liner:
- Remove tank flap unit with rubber cup -1-.
- Pull vacuum hose for fuel system leak detection pump -2- off union.
- Remove 3-pin connector -3- and disconnect wiring.
- Pull pressure hose -5- off.
Note: To unlock, press the safety ring (arrow) into the EVAP canister.
- Remove fuel system leak detection pump -4- with detection pump air filter and bracket by pulling from center forward and then sliding downward.
- Pull breather lines -3- and -4- off by pressing safety rings at EVAP canister (arrows) on upper and lower part together and Unclipping breather line -3- out of clip -1-.
- Remove bolts -2-.
- Unclip vacuum line -1- at fuel tank.
- Disconnect breather line -2-.
WARNING:
^ The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
^ Always wear eye protection and wear fuel-resistant gloves when disconnecting system connections.
- Loosen spring-type clamp -3- and pull supply hose off fuel line. Collect leaking oil.
- Seal lines to avoid contamination of fuel system.
- Support fuel tank with engine/transmission jack V.A.G. 1383 A and unscrew bolts (arrows).
Note: To prevent paint work being damaged place a textile or rubber mat between fuel tank and jack
- Lower fuel tank.
Installing
Installation is performed in reverse order to removal, considering the following:
^ The tensioning strap rubber profile must not be damaged.
^ Replace bolts (arrows).
^ Guide wiring on EVAP canister must be securely connected. Check for correct seat by tightening.
- Adapt (match) engine control module to throttle valve control module, Refer to Adapting components and functions.
- Generate readiness code again if DTC memory has been erased or engine control module was disconnected from permanent positive.