Fuel Tank, Removing and Installing

Fuel Tank, Removing and Installing

Special tools, equipment, test and inspection devices; required accessories








- VAG 1331 torque wrench (5 - 50 Nm) or equivalent







- VAG 1383 A engine/transmission jack

Removing
- Review safety measures before starting work.


NOTE: The battery ground strap must eventually be disconnected in the further course of work. Check whether the vehicle has a coded radio system. It may be necessary to disable the theft-deterrent feature by entering the appropriate code.


- Disconnect battery ground strap with ignition off.
- Open fuel filler door.
- Remove rear right fender liner:
- Remove rear axle:







- Remove covers underneath fuel tank -arrows-
- Empty tank and clean around fuel filler tube.
- Remove retaining screw and fuel filler door module together with rubber seal.
- Remove retaining screw on filler neck.
- Remove vent lines on charcoal canister.


NOTE: Press the buttons on the hose couplings together for this.


- Seal lines so that no dirt can get into fuel system
- Fold rear seat bench forward.
- Remove cover underneath seat bench.







- Remove 4-way connector -arrow-from flange.







- Separate return line -2- (blue), feed line -1- (black) and vent line -3- (white) at joint.


NOTE: Press the tabs on the hose couplings together.


CAUTION!
The feed line is under pressure! Place clean rags around the hose connections, then reduce the pressure by disconnecting the hose very slowly and carefully.


- Cover lines so that no dirt can get into fuel system.
- Remove tightening straps. Support fuel tank with VAG 1383 A engine/transmission hoist.
- Lower fuel tank.

Installing
Install in reverse sequence, but note the following:
- Route the vent and fuel hoses without creasing them.
- Make sure a tight fit for the fuel hoses.
- Do not reverse the feed and return hoses (return line blue or with blue marking, feed line black).


NOTE: Once the fuel tank is installed, Make sure that the feed, return, and vent lines are still clipped onto the fuel tank.


- Check DTC memory:
- Perform basic settings.
- Read readiness code:
- If fault memory was erased or engine control module was disconnected from positive voltage supply, readiness code must be regenerated: