Removal and Replacement

Fuel Tank

Special tools, testers and auxiliary items required

• Fuel Extracting Device (VAS 5190)

• Wrench (T10202)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Engine/Transmission Jack (V.A.G 1383 A)

Requirements

The fuel tank must be drained. Refer to => [ Fuel Tank, Draining ] Procedures.

Removing

- Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.

- Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

- Remove the mufflers and mounts.

- Remove the rear driveshaft.

- Remove the rear subframe.

- Open the fuel tank flap and remove fuel tank cap.

- Pull the rubber gasket off the filler neck.

- Remove the bolts - 1 - for the filler neck and remove the ground wire - 2 -.





- Remove the right rear wheel housing liner.

- Remove the cover bolts - arrow - and cover.





- Unclip the breather lines that are secured on the longitudinal member with clips from the fuel tank.





- Remove the filler neck bolt - arrow - in the wheel housing.





- Disconnect the connector to the left fuel pump near the fuel tank.





- Remove the securing straps with covers on left and right below fuel tank.

- Support the fuel tank using (V.A.G 1383 A) and remove the strap at the center of the fuel tank.

- Carefully lower the fuel tank about 30 cm.

- Reach between the fuel tank and the vehicle floor and disconnect the fuel line from the flange. When disconnecting the fuel supply line, hold a cloth around the line connection.

• This step eliminates having to cut open the carpeting in the vehicle interior in the vicinity of flange cover.

- Lower the fuel tank.

Installing

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

• Do not interchange the supply and return lines (return line is blue or has a blue mark - 1 -, supply line is black - 2 -).





• Connections for breather and fuel lines must engage audibly when joined.

• Fuel lines clipped to the fuel tank.

• Make sure the ventilation and fuel lines are not kinked when installed.

• Ensure the fuel lines are securely seated.