Fuel Tank

Engine Code BPR (Metal Fuel Tank)

Fuel Tank

Special tools, testers and auxiliary items required

• Torque wrench (5-50 Nm) (VAG 1331)

• Engine and transmission jack (VAG 1383A)

• Rubber or textile mat

Removing

• Fuel tank must be empty.

• Empty the fuel tank if necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Description and Operation.

• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Description and Operation.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Description and Operation.

- First, check whether a coded radio is installed. If necessary, obtain the anti-theft code.

- If necessary, take out the adapter for the wheel rim lock from the luggage compartment.

- Open the fuel filler flap and loosen the fuel filler cap.

- With ignition switched off, disconnect the battery ground (GND) cable.

- Fold the rear seat bench forward.

- Remove the cover from the fuel delivery unit.

- Disconnect the 4 pin connector - 1 -.





- Remove the bolt for the tank door unit and remove the tank door unit.

- Remove the rear axle beam.

- Remove the rear part of the exhaust system. Refer to => [ Muffler with Mounts Assembly Overview ] Muffler With Mounts Assembly Overview.

- Remove the rear right wheel housing liner.

- Remove the protective plate - A - bolts - arrows -.





- Disconnect the vent lines - 1 and 2 -.





Press in the securing ring - A - to disengage the lines.

- Disconnect the vacuum line - 3 - and remove it from the bracket - arrow -.





- Remove the brace - 2 -.

- Remove the bolts - 1 -.

CAUTION!
Fuel system is under pressure!

• Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before loosening the line connection, place a cloth around the connection point. Then release pressure by carefully loosening the line connection.

- Unclip the vacuum line - 1 - from the fuel tank.





- Disconnect the vent line - 2 -.

- Loosen the spring clamp - 3 - and disconnect the supply hose from the supply line. Catch any leaking fuel.

- Seal the lines so that the fuel system is not contaminated by dirt etc.

- Remove the bolts - arrows -. Support the fuel tank using the (VAG 1383A) while doing so.





• In order to prevent damage to the paint, a textile or rubber mat must be placed between the fuel tank and the (VAG 1383A ).

- Lower the fuel tank.

Installing

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

• Rubber the profile of the tensioning strap must not be damaged.

• Replace the bolts - arrows -.





• Line connections on the Evaporative Emission (EVAP) canister must be engaged correctly. Check for secure fitting by pull on the connections.

- Bleed the fuel supply system. Refer to => [ Fuel System, Bleeding ] Description and Operation.

- Connect the battery.