Fuel Tank, Removing and Installing

Fuel tank, removing and installing

Special tools and equipment





- V.A.G. 1331 Torque wrench (5 to 50 Nm)





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

Removing

Note:
^ Observe safety precautions before starting work.
^ The fuel extraction unit VAS 5190 is recommended for emptying the fuel tank.

- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Open fuel flap.
- Drain fuel tank and clean fuel filter neck and surrounding area.
- Remove securing bolt on filler neck.
- Fold rear seat bench forward.
- Remove cover from under fuel tank.
- Remove rear axle

WARNING:
^ The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
^ Always wear eye protection and wear fuel resistant gloves when disconnecting system connections.

- Remove cover from fuel delivery unit.





- Disconnect 4- pin connector off flange (arrow).





- Remove cover from under the fuel tank (arrow)





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

Note: To do this, press buttons on hose couplings.

WARNING:
^ The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
^ Always wear eye protection and wear fuel resistant gloves when disconnecting system connections.

- Seal the lines so that the fuel system is not contaminated by dirt etc.
- Remove tensioning strap. When doing this support fuel tank with engine and transmission jack V.A. G 1 383 A.
- Lower fuel tank.

Installing
Installation is performed in reverse order to removal, note the following:
^ Install breather and fuel hoses free of kinks.
^ Secure fuel hoses with spring-type clips
^ Ensure fuel hoses are tight.
^ Do not interchange supply and return hoses (return line blue or blue markings, supply line black)

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

- Adapt (match) engine control module to throttle valve control module, Refer to Adapting components and functions.
- Generate readiness code again if DTC memory has been erased or engine control module was disconnected from permanent positive, Refer to Adapting components and functions.