Fuel Tank, Removing and Installing

Fuel Tank, Removing And Installing (Engine Code BBW)

Special Tools And Equipment







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







- V.A.G 1383 A Engine/transmission jack
- Textile or rubber mat

Requirement
- Fuel tank must be empty

Removing

NOTE:
- Observe safety precautions before starting work.
- The fuel extraction unit VAS 5190 is recommended for emptying the fuel tank. Contrary to the operating instructions the draining must not occur via the filler neck in this engine/vehicle or inner components will be damaged. Empty fuel tank only via the open flange, Removing and installing fuel delivery unit.

- Open fuel flap.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Fold rear seat bench forward.
- Remove cover from fuel delivery unit.







- Disconnect 4-pin connector -1-.
- Unscrew nuts -2- and take flange -3- off.
- Drain fuel tank via flange opening, e.g. with VAS 5190.
- Bolt on flange again, Installing fuel delivery unit.
- Remove rear axle:
- Remove rear part of exhaust system.
- Remove right rear wheelhousing liner:
- Clean fuel filler neck and EVAP canister area.







- Remove tank flap unit with rubber cup -1-.
- Pull vacuum hose for fuel system leak detection pump -2- off union.
- Remove 3-pin connector -3- and disconnect wiring.
- Pull pressure hose -5- off.

NOTE: To unlock, press the safety ring (arrow) into the EVAP canister.

- Remove fuel system leak detection pump -4- with detection pump air filter and bracket by pulling from center forward and then sliding downward.







- Pull breather lines -3- and -4- off by pressing safety rings at EVAP canister (arrows) on upper and lower part together and unclipping breather line -3- out of clip -1-.
- Remove bolts -2-.







- Unclip vacuum line -1- at fuel tank.
- Disconnect breather line -2-.

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..

- Loosen spring-type clamp -3- and pull supply hose off fuel line. Collect leaking oil.
- Seal lines to avoid contamination of fuel system.







- Support fuel tank with engine/transmission jack V.A.G 1383 A and unscrew bolts (arrows).

NOTE: To prevent paintwork being damaged place a textile or rubber mat between fuel tank and jack.

- Lower fuel tank.

Installing
Installation is performed in reverse order to removal, considering the following:

- Tensioning strap rubber profile must not be damaged.







- Replace bolts (arrows).
- Guide wirings on EVAP canister must be securely connected. Check for correct seat by tightening.

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