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







- V.A.G 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft lb), or equivalent







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

Removing
- Note safety precautions before starting work.
- Open fuel flap.


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


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







- Remove covers under fuel reservoir
- Drain fuel tank, clean fuel filler neck and surrounding area.
- Remove screws and fuel filler door with rubber seal.
- Remove filler neck mounting bolts.
- Disconnect vent lines at fuel filler neck
- Remove vent lines from EVAP canister


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 forwards.
- Remove fuel gauge sensor cover plate.







- Remove 4 pin connector (arrow) from fuel delivery unit.


WARNING!
Fuel supply lines are underpressure! 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 V.A.G 1383 A engine/transmission jack.
- Lower fuel tank.

Installing
Installation is the reverse order of removal, note the following:
- Breather and fuel hoses must be installed kink-free.
- Ensure fuel hoses are seated securely.
- 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:
- Match Engine Control Module to Throttle Control Module:
- Check Readiness code:
- If DTCs are stored in the ECM or ECM receives low voltage when ignition is on, Readiness code must be reset: