Removal and Replacement

Fuel Tank

Special tools, testers and auxiliary items required

• Fuel Extracting Device (VAS 5190)

• Wrench (T10202)

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

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Engine/Transmission Jack (V.A.G 1383 A)

Removing

• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.

• The fuel tank must be drained. Refer to => [ Fuel Tank, Draining ] Procedures.

Vehicles with Engine Code BKW:

- Remove the middle and rear mufflers from the exhaust system. Refer to => [ Muffler and Mounts ] Muffler and Mounts.

Vehicles with Engine Code BWF:

- Remove the rear muffler from the exhaust system. Refer to => [ Muffler and Mounts ] Muffler and Mounts.

Continuation for all Vehicles:

- Remove the rear driveshaft.

- Remove the rear subframe.

- Open the fuel tank flap and remove the fuel cap.

- Pull the rubber gasket off the filler neck.

- Remove the bolts - 1 - for the filler neck and pull off the ground wire - 2 -.






- Remove the right rear wheel housing liner.

- Remove the protective cover retainers - arrow -.






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






- Remove the bolt - arrow - for the fill pipe in the wheel housing.






- Disconnect the fuel pump connectors, on the left next to fuel tank.






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

- Support the fuel tank using the engine/transmission jack (V.A.G 1383 A) and remove the strap in the center of fuel tank.

- Carefully lower the fuel tank about 30 cm.

- Between the fuel tank and the vehicle floor and disconnect the fuel lines from the sensor flange. When pulling off the fuel supply line, hold a cloth around fuel supply line.

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

- Lower and remove the fuel tank.

Installing

Installation is performed in the reverse order of removal, noting the following:

• Line connections for metering, ventilation and fuel lines must engage audibly when joined.

• Do not interchange the supply and return lines (return line - 1 - is blue or has a blue mark, supply line - 2 - in black).






• Clip in the metering and fuel lines at the fuel tank.

• Make sure the metering, ventilation and fuel hoses are not kinked when installed.

• Make sure the metering and fuel lines are securely positioned.