Fuel Tank, Removing and Installing

Fuel Tank, Removing And Installing

Special tools, testers and auxiliary items required







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







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

Removing
Observe safety precautions.
Observe rules for cleanliness.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- Open fuel flap.
- With ignition switched off disconnect battery ground strap.
- Remove rear axle: Suspension, Wheels, Steering
- Remove right rear wheelhousing liner: Body Exterior







- Remove fuel tank cover.
- Drain fuel tank and clean fuel filler neck and surrounding area.
- Unscrew securing bolt and remove tank flap unit with rubber cup.
- Remove securing bolts on filler neck.
- Fold rear seat bench forward.
- Remove cover plate from fuel gauge sender and disconnect connector from flange.







- Disconnect supply and return lines on right front of fuel tank.

CAUTION:
- The fuel and the fuel lines in the fuel system can become very hot (danger of scalding).
- The fuel system is also under pressure. Before opening the system, place cloths around the connection. Then carefully loosen the connection to release the pressure.
- Wear eye and hand protection when performing any type of repair work on the fuel system.

NOTE: Press buttons on hose couplings - arrows - to disconnect fuel line connections.

- Remove tensioning strap. When doing this support fuel tank with engine/transmission jack V.A.G 1383 A.
- Lower fuel tank.

Installing
Installation is performed in reverse order of removal. Note the following:
- Install breather and fuel hoses free of kinks.
- Ensure fuel hoses are tight.
- Do not interchange supply and return lines (return line = blue or blue markings, supply line = black).
- Clip supply and return line onto fuel tank.

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