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. 1 383 A Engine/ transmission jack
- Textile or rubber mat

Requirements
^ 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.

- 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.
- Remove rear axle:
- Remove rear part of exhaust system.
- Remove rear right wheel housing liner:





- 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 paint work 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:
^ The tensioning strap rubber profile must not be damaged.





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