Fuel Tank, Removing and Installing

FUEL TANK, REMOVING AND INSTALLING

Special tools, testers and auxiliary items required




- Engine/transmission jack V.A.G 1383 A




- Torque wrench VAG 1331

VEHICLES WITH ALL WHEEL DRIVE (AWD)


- Read safety precautions before beginning work.
- Open fuel filler flap.
- Determine whether a coded radio is installed. In this case, determine the anti-theft coding.
- Disconnect battery Ground (GND) strap with the ignition switched off.
- Remove right rear wheelhousing liner.
- Empty fuel tank and clean area surrounding fuel filler tube.
- Remove mounting bolt and remove fuel flap unit with rubber cap.
- Remove mounting bolt at fuel filler tube.
- Remove shielding plate for fuel filler tube.
- Remove center and rear muffler of exhaust system.
- Remove rear axle.

CAUTION!
Fuel supply line is under pressure! Before loosening hose connections, place rags around the connection point. Then release pressure by carefully pulling on hose.






- Disconnect supply line - 1 - from fuel filter input.
- Mark return line - 2 - and ventilation line - 3 - and disconnect at connection points.
- Remove shielding plate at left and right on fuel tank and on underbody.
- Remove tension straps. Support fuel tank using engine/transmission jack V.A.G 1383 A while doing so.






- Lower engine-/transmission jack V.A.G 1383 A only so far until harness connector on flange - arrow - can be disconnected.
- Lower fuel tank.


Installing

Installation is the reverse of removal, noting the following:

- Make sure vent and fuel lines are not kinked when installed.
- Make sure fuel lines are securely fastened.
- Secure fuel lines with spring type clamps.
- Do not mix-up supply and return lines (return line is blue or has blue marking, supply line is black).

Note: After installing fuel tank, check to be sure supply, return and vent lines are still clipped in at fuel tank.


FRONT WHEEL DRIVE (FWD) VEHICLES

Read safety precautions before beginning work.

- Open fuel filler flap.
- Determine whether a coded radio is installed. In this case, determine the anti-theft coding.
- Disconnect battery Ground (GND) strap with the ignition switched off.
- Remove rear right wheelhousing liner.
- Empty fuel tank and clean area surrounding fuel filler tube.
- Remove mounting bolt and remove fuel flap unit with rubber cap.
- Remove mounting bolt at fuel filler tube.

CAUTION!
Fuel supply line is under pressure! Before loosening hose connections, place rags around the connection point. Then release pressure by carefully pulling on hose.






- Disconnect supply line - 1 - from fuel filter input.
- Mark return line - 2 - arid ventilation line - 3 - and disconnect at connection points.
- Remove tension straps. Support fuel tank using engine/transmission jack V.A.G 1383 A while doing so.





- Lower engine/transmission jack V.A.G 1383 A only so far until harness connector on flange - arrow - can be disconnected.
- Lower fuel tank.


Installing

Installation is the reverse of removal, noting the following:

- Make sure vent and fuel lines are not kinked when installed.
- Make sure fuel lines are securely fastened.
- Secure fuel lines with spring type clamps.
- Do not mix-up supply and return lines (return line is blue or has blue marking, supply line is black).

Note: After installing fuel tank, check to be sure supply, return and vent lines are still clipped in at fuel tank.