Fuel Tank with Attachments

Fuel Tank with Attachments

Special tools, testers and auxiliary items required

• Fuel siphoning unit (VAS 5190)

• Wrench (T10202)

• Torque wrench (V.A.G 1331)

• Torque wrench (V.A.G 1332)

• Engine/transmission jack (V.A.G 1383 A)

Requirements

• Fuel tank must be drained --> [ Fuel Tank, Emptying ] Procedures,

• Fuses - 13 - and - 14 - - arrow - must be removed from their sockets.





Removing

- Read safety precautions before beginning work --> [ Safety Precautions ] Safety Precautions.

CAUTION!
Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

First, relieve fuel pressure as follows:

- Place a rag around connection to catch escaping fuel.

- Disconnect fuel supply line - arrow - in engine compartment.





When fuel pressure has been released:

- Remove mufflers and mountings.

- Remove drive shaft tube.

- Remove rear axle.

- Open fuel flap and remove fuel tank cap.

- Pull rubber gasket off filler neck.

- Remove securing bolts - 1 - on filler neck and remove Ground (GND) wire - 2 -.





- Remove right rear wheel housing liner.

- Remove cover plate - arrow -.





- Unclip fuel tank breather lines at securing clip attached on longitudinal member.





- Remove securing bolts for filler tube - 1 - and EVAP canister - 2 - in wheel housing.





- Bend filler neck slightly downward and pull off breather line connections to EVAP canister.





• Release connection by pressing button on hose coupling.

- Disconnect Ground (GND) wire clipped to EVAP canister and remove canister.

- Separate fuel pump connectors, on left next to fuel tank.





- Remove securing straps with covers on left and right below fuel tank.

- Support fuel tank using Engine/transmission jack (V.A.G 1383 A) and remove tension strap at center of fuel tank.

- Carefully lower fuel tank about 30 cm.

CAUTION!
Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

- Grab between fuel tank and vehicle floor and hold a rag over the fuel supply hose. Disconnect the supply and vent lines from flange.

• This step eliminates having to cut open the carpeting in the vehicle interior in the vicinity of sensor flange cover.

- Lower fuel tank.

Installing

Installation is in reverse order of removal, note the following:

• Connections for breather and fuel lines must engage audibly when joined.

• Make sure ventilation and fuel lines are not kinked when installed.

• Secure fuel hoses with spring-type clamps.

• Ensure fuel hoses are seated securely.

• The Ground (GND) strap - 2 - must be securely connected to body.





• Before fastening the fuel tank, check that the supply and ventilation lines are still clipped onto the fuel tank.