Fuel Tank, Removing and Installing

Fuel tank, removing and installing

WARNING: Fire hazard! Do NOT have anything in the area that can ignite gasoline!

Special tools, test equipment and auxiliary items





^ VAG1331 Torque wrench 5 to 50 Nm (3 7 to 37 ft. lbs.), or equivalent





^ VAG1383 A Engine/transmission jack

Removing
- Note safety precautions before starting work

CAUTION: Obtain radio anti-theft code from customer BEFORE disconnecting battery Ground strap.

- With ignition switched OFF, disconnect battery Ground.
- Open fuel flap.
- Remove right, rear wheel housing liner
- Remove rear axle





- Remove covers under fuel reservoir
- Drain fuel tank and clean fuel filler neck and surrounding area.
- Unscrew securing bolts and remove tank flap unit with rubber cup.
- Remove securing bolts on filler neck.
- Disconnect vent lines at fuel filler neck
- Remove vent lines from EVAP canister
- Disconnect gravity valve / expansion valve

Note: Press down on fuel line connectors to release.

- Cover ends of open lines to prevent fuel system contamination with dirt
- Fold rear seat bench forward.
- Remove fuel gauge sensor cover plate.





- Remove 4 pin harness connector -arrow- from fuel delivery unit.
- Remove cover from under fuel tank

WARNING: Fuel supply lines are under pressure! Before removing hose connection, wrap a cloth around the connection. Then release pressure carefully when pulling hose off connection.





- Disconnect return hose -2- (blue), supply hose -1- (black) and breather hose -3- (white) at connecting points.

Note: Press down on fuel line connectors to release.

- Cover ends of open lines to prevent fuel system contamination with dirt
- Remove tensioning strap by supporting fuel tank with VAG1383 A engine/transmission jack.
- Lower fuel tank.

Installing
Installation is carried out in the reverse order of the removal procedure, when doing this note the following:
^ Breather and fuel hoses must be installed kink free.
^ Make sure fuel hoses are seated securely.
^ Guide vent lines through the opening in the long member (install wire routing)
^ Secure vent lined on filler neck with spring clamp
^ Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).

Note: After installing fuel gauge sensor, ensure that the supply, return and breather lines are still clipped onto the fuel tank.

- Check DTC memory:
- Refer to Powertrain Management

Replacement fuel tanks, installing grounding wire
All replacement fuel tanks do not come with grounding wire installed.
The grounding wire must be installed into all replacement fuel tanks.

CAUTION: Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information.

Install grounding strap Part No. 1 JO 201 184 into replacement fuel tank as follows:
- Remove fuel filler cap -note cautions written on cap.





- Bend up tab on inside of fuel filler pipe as shown -arrow-.

Note: Illustration shows grounding strap already installed





- Insert end -A- of ground strap through slot in tab up to bend -B- at other end of strap.
- Bend down tab on inside of fuel filler pipe. This will secure strap to end of tab.
- Reinstall fuel filler cap.