Removal and Replacement

Fuel Tank

Special tools, testers and auxiliary items required

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

• Torque wrench (V.A.G 1331)

Removing

• Read safety precautions => [ Safety Precautions ] Fuel Supply, and rules of cleanliness => [ Clean Working Conditions ] Fuel Supply, before beginning work.

- First, check whether a coded radio is installed. If necessary, obtain the anti-theft coding.

- Disconnect battery Ground (GND) cable with the ignition switched off.

- Open the fuel tank flap.

- Drain the fuel tank => [ Fuel Tank, Draining ] Fuel Tank, Draining.

- Remove the fuel flap unit together with the rubber gasket.

- Fold rear seat bench forward.

- Remove the cover plate from the fuel delivery unit and disconnect the connector.

- Remove rear axle.

- Remove rear right wheel housing liner.

- If equipped, remove the protective cover - 1 -- arrows -.





- If equipped, remove the fuel tank covers- arrows -.





- Clean the area around the fuel filler tube (remove the lid).

- Disconnect vent lines on the filler tube.

- Remove the gravity valve from the bracket.

- Remove securing bolts on filler neck.

CAUTION!
• The fuel or fuel lines in fuel system can become very hot (danger of scalding)!

• In addition, the fuel system is under pressure! Before opening the system, place cloths around the connection area and release pressure by carefully loosening the connection!

• Wear protective goggles and protective gloves when working on the fuel system!

- Separate fuel supply line and return line on front right at fuel tank.





• To release the fuel lines, compress the circlip - arrows -.

- Seal the lines so that the fuel system is not contaminated by dirt etc.

- Remove tensioning strap. Support fuel tank using engine/transmission jack (V.A.G 1383 A) while doing so

- Lower fuel tank. When doing this, guide vent lines through opening in longitudinal member.

Installing

Installation is performed in reverse order. When doing this note the following:

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

• Make sure fuel lines are securely fastened.

• Guide the vent lines through the opening in the longitudinal member (install the line guide).

• Use spring-type clips to secure the vent lines to the filler tube.

• Do not interchange supply and return lines (return line is blue or has blue marking, supply line is black).

• After installing fuel tank, check whether supply and return lines are still clipped in at fuel tank.

- Connect battery