Fuel Tank, Removing and Installing

Fuel tank, removing and installing
Special tools and equipment





^ VAG1383A Engine/transmission jack





^ VAG1331 Torque wrench (5-50 Nm)

Removing
- Note safety precautions before starting work.
- First check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Open fuel flap.
- Remove rear right wheel housing liner.
- Remove rear axle.
- Drain fuel tank and clean fuel filler neck and surrounding area.
- Unscrew securing bolts and remove tank flap unit with rubber cup.
- Remove securing bolt on filler neck.
- Fold rear seat bench forward.
- Remove fuel gauge sensor cover plate and disconnect connector.
- Remove cover from under fuel tank.

WARNING:Fuel supply hoses are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.





- Disconnect return hose -2- (blue), supply hose -1- (black) and breather hose -3- (white) at connecting point.

Note: Press buttons on hose couplings to do this.

- Remove tensioning strap. When doing this support fuel tank with engine/transmission jack VAG1383A.
- Lower fuel tank.

Installing
Installation is carried out in the reverse order; when doing this note the following:
^ Breather hoses are to be installed kink-free.
^ Fuel hoses are to be installed kink-free.
^ Ensure fuel hoses are seated securely.
^ Secure fuel hoses with spring-type clamps.
^ Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).

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

- Check DTC memory.
- Read readiness code.
- Match engine electronics control module to throttle valve control module.