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

Note:
- The fuel tank must not be more than 1/3 full.
- Empty fuel tank if necessary using Fuel siphoning device VAS 5190 or FM3000GH Fuel Extractor.
- Observe safety precautions.

REMOVING

1. Open fuel filler door and remove fuel tank cap.
2. First, check whether a coded radio is installed. If necessary, obtain the antitheft coding.
3. Switch off ignition and all electrical consumers.
4. Disconnect battery Ground (GND) strap.
5. Remove the rear seat bench.
6. Remove cover from fuel pump / fuel delivery unit.






7. Remove 4-pin connector - arrow - from flange on fuel tank.
8. Remove center and rear muffler of exhaust system.
9. Remove subframe.
10. Remove right rear wheelhouse liner.
11. Remove shielding plate for fuel filler tube.
12. Clean area surrounding fuel filler tube.
13. Remove bolts for fuel filler door unit and remove fuel filler door unit with rubber cap.
14. Remove securing bolts on filler neck.


CAUTION!

Fuel supply line is under pressure! Wear eye protection and protective clothing in order to avoid injuries by contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.






15. Pull supply hose - 1 - from fuel filter.
16. Mark return hose - 2 - and breather hose - 3 - and separate at connecting point.
17. Seal the lines so that the fuel system is not contaminated by dirt etc.
18. Remove shielding plates at left and right on fuel tank and on underbody.
19. Remove cover from EVAP canister.






20. Disconnect vent lines at EVAP canister - arrows -.
21. Seal lines so that the fuel system is not contaminated by dirt etc.
22. Remove tensioning strap. Support fuel tank using engine/transmission jack V.A.G 1383 A while doing so.
23. Lower fuel tank.


INSTALLING

Installation is performed in the reverse order of removal, noting the following:

- Make sure vent and fuel lines are not kinked when installed.
- Ensure fuel hoses are seated securely.
- Secure fuel hoses with clamps.
- Do not interchange supply and return hoses (supply hose with white lettering, return hose with blue lettering).

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

- Check DTC memory of all control modules, repair all stored malfunctions, and erase DTC memory afterwards.
- After erasing DTC memory, readiness code must be generated again.