Volkswagen Workshop Service and Repair Manuals

Removing and installing fuel tank Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Engine and gearbox jack -V.A.G 1383 A-

t  Removal wedge -3409- Removing –  Observe safety precautions → Chapter. –  Observe rules for cleanliness → Chapter. –  Check whether a coded radio is fitted. If so, obtain anti-theft code: –  Disconnect battery earth → Electrical system; Rep. gr.27.   Caution To prevent damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery.

–  Open tank flap. –  Remove cap -arrow- from fuel filler neck. –  Clean area around fuel filler neck. –  Drain fuel tank completely → Chapter. –  Remove tank flap unit → General body repairs, exterior; Rep. gr.55. –  Remove bench seat → General body repairs, interior; Rep. gr.72.

–  Unclip cover -1- at retaining tabs -arrows-, using removal wedge -3409-.

–  Release and pull off connector -1-. –  Remove rear right wheel → Wheels, tyres, wheel alignment; Rep. gr.44.

–  Unscrew bolts -arrows- of filler neck -1- from body structure.   Note The aid of a 2nd mechanic is required to remove the rear part of the exhaust system.

Vehicles with clamp on exhaust system –  If fitted, loosen clamp -arrows-.

Vehicles without clamp on exhaust system On vehicles without clamp on exhaust system, separate exhaust system → Rep. gr.26. Continuation for all vehicles

–  Remove exhaust system cross member -1- from underbody -2-. –  Unscrew nuts -arrows-.

–  Remove rear bracket -1- for exhaust system -2-. –  Remove bolt -arrow-. –  Remove rear silencer → Rep. gr.26.   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 fuel lines. Separate push-on couplings → Chapter. –  Lower rear axle → Rep. gr.42 → Running gear, axles, steering; Rep. gr.42.

–  Place engine and gearbox jack -V.A.G 1383 A- under fuel tank to support it.

–  Unscrew bolts -arrows- on fuel tank -1-.   Note The aid of a 2nd mechanic is required to remove the fuel tank. –  Lower fuel tank and guide it out of the body structure. If fuel tank is to be renewed, remove activated charcoal filter → Chapter. Installing Install in reverse order. In the process, note the following: t  Take installation position of earth connection into account → Fig. t  Make sure that the filler neck of the fuel tank is correctly inserted into the opening in the body. t  Use engine and gearbox jack -V.A.G 1383 A- to position fuel tank on underbody. t  Ensure proper seating of activated charcoal filter. t  Install breather and fuel lines free of kinks. t  Ensure that line connections are tight. t  After installing fuel tank, check that supply and breather lines are still clipped onto fuel tank.

Specified torque

Component	Specified torque
Filler neck of fuel tank to body t  Renew.	8 Nm + 90°
Fuel tank to underbody t  Renew.	20 Nm + 90°
Bench seat	→ General body repairs, interior; Rep. gr.72
Exhaust system	→ Rep. gr.26
Tank flap unit	→ General body repairs, exterior; Rep. gr.55.