Fuel Tank, Removing and Installing

Fuel Tank, Removing And Installing

Special tools, testers and auxiliary items required







- Torque wrench (5...50 Nm) V.A.G1331







- Engine/transmission jack V.A.G1383A

Not illustrated:
- Container for removed components V.A.G 1698
- Engine plug set VAS 6122

Removing

NOTE:
- The fuel tank must not be more than 1/3 full.
- Empty fuel tank using fuel suction unit VAS5190 if necessary.


- Observe safety measures before performing repair work.
- Turn ignition and all electrical consumers off and remove ignition key.
- With ignition switched off disconnect battery ground strap.


NOTE: All cable ties which are opened or cut open when removing must be replaced in the same position when installing.


- Remove rear right wheelhousing liner.
- Remove center and rear mufflers (left and right sides) of exhaust system26-1, Muffler with mountings.

- Remove driveshaft:
- Vehicles with manual transmission
- Vehicles with automatic transmission

- Remove rear axle:
- Drain fuel tank and clean fuel filler neck and surrounding area.
- Fold rear seat bench forward.
- Remove cover from fuel delivery unit.







- Remove 4-pin connector- arrow -from flange on fuel tank.
- Pull connecting hose off union to additional fuel tank Item - 7 -.







- Remove vent pipe from EVAP canister - 1 - at junction piece and vent pipe from additional fuel tank - 2 - at filler neck.
- Seal lines so that fuel system is not contaminated by dirt etc.
- Remove securing bolts - 3 - on lower filler neck.
- Remove fuel filler cap from fuel filler tube.
- Remove bolts and remove tank flap unit with rubber cup.
- Remove bolts on filler neck.







- Pull supply hose - 1 - from fuel filter.
- Mark return hose - 2 - and breather hose - 3 - and separate at connecting point.


CAUTION: Fuel supply lines are under pressure. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.


- Seal lines so that fuel system is not contaminated by dirt etc.
- Remove left and right protective plates on fuel tank and floor.
- Remove tensioning strap. Support with engine/transmission jack V.A.G1383A when removing.
- Lower using engine/transmission jack V.A.G1383A but only enough to allow connector for fuel gauge sender to be pulled off flange.







- Remove supply line - 1 - from fuel delivery unit in additional fuel tank at filler neck.
- Seal pipes so that fuel system is not contaminated by dirt etc.
- Lower fuel tank.

Installing
Installation is performed in the reverse order of removal, noting the following:
- Breather and fuel hoses are to be installed kink-free.
- Ensure fuel hoses are seated securely.
- Secure fuel hoses with spring-type clamps.
- Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).


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