Fuel Tank, Removing and Installing

Fuel Tank, Removing and Installing

Special tools



- VAG 1383 A Engine/transmission jack




- VAG 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft lb) or equivalent

Removing
- Before beginning any work, observe cautions. Technician Safety Information

WARNING!
- Fuel supply lines are under pressure!
- Before removing hose connections wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

CAUTION!
Obtain radio anti-theft code before disconnecting battery Ground strap.

- Open fuel filler cap.
- Obtain radio anti-theft code.
- With ignition switched off, disconnect battery ground strap.
- Remove right rear wheel housing liner:
- Remove rear axle:




- Remove cover from fuel tank (arrows)
- Drain fuel tank, clean fuel filler neck and surrounding area.
- Remove bolts and remove fuel filler assembly with rubber cup.
- Remove bolts at fuel filler assembly.
- Move rear seat backrest forward.
- Remove cover from fuel gauge sensor and disconnect electrical connector.




- Disconnect fuel supply and return lines at right front of fuel tank.

NOTE: To disconnect fuel lines push hose couplings (arrows).

- Cap lines to prevent dirt from entering system.
- Remove support straps while supporting tank with engine/transmission support VAG 1383.
- Carefully lower fuel tank.


Installing
Install fuel tank in reverse order of removal and note the following:
- Route supply and return lines without bending or kinking.
- Check proper fit of fuel lines.
- Do not interchange supply and return hoses (return: blue with blue markings; supply: black).
- Clip supply and return lines to fuel tank.


NOTE: After installing the fuel tank, check that the fuel return and supply lines are still clipped to the fuel tank.

- Adapt engine electronics to throttle control module:
- Read readiness code.

If the DTC memory was erased or the engine control module is subject to low voltage with ignition ON, reset readiness code.