Volkswagen Workshop Service and Repair Manuals

Removing and installing fuel tank Special tools and workshop equipment required

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

t  Engine and gearbox jack -V.A.G 1383 A- Removing –  Note safety precautions before starting work → Chapter. –  First check whether a coded radio is fitted. If so, obtain anti-theft coding. –  With the ignition switched off, disconnect battery earth strap. –  Unscrew securing bolts and remove tank flap unit. –  Drain fuel tank and clean fuel filler neck and surrounding area. –  Fold rear seat bench forwards. –  Remove cover from fuel delivery unit.

–  Pull 4-pin connector -1- off flange. –  Remove right rear wheel. –  Remove rear right wheel housing liner → General body repairs, exterior; Rep. Gr.66.

–  Pull off pressure retention valve -1- and breather pipe -2- (push circlip). –  Unbolt filler neck from body. –  Unscrew all rear exhaust system retainers from body. Support lowered exhaust system on body with suitable wire. –  Remove rear axle: → Running gear, axles, steering; Rep. Gr.42.   WARNING Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Disconnect return hose -2- (blue), supply hose -1- (black) and breather hose -3- (white) at connecting point.   Note Press in securing ring to release fuel lines. –  Remove securing strap bolt and securing strap. When doing this, support fuel tank with engine and gearbox jack -V.A.G 1383 A-. –  Lower fuel tank. Installing Installation is performed in the reverse sequence. When doing this, note the following: t  Install breather and fuel lines free of kinks. t  Ensure that fuel line connections are tight. t  After installing fuel tank, check that the supply, return and breather pipes are still clipped onto the fuel tank.

t  Note connections at activated charcoal canister -3-. Pressure retention valve -1- must be on the outside.