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Testing fuel pump > < Removing and installing the sender for fuel gauge displayG

Octavia Mk2

Removing and installing the fuel tank
Removing and installing the fuel tank
Special tools and workshop equipment required
t  Engine/gearbox jack, e.g. -V.A.G 1383 A-
Removing
l  The fuel tank must not be more than 1/4 full.
l  Ignition and all electrical components switched off, ignition key withdrawn.
  Note
t  Empty the fuel tank if necessary → Chapter.
t  Observe the safety instructions before starting fitting work → Chapter.
t  Observe rules for cleanliness → Chapter.
–  Removing rear seat bench → Body Work; Rep. gr.72.
–  Remove the cover from the fuel delivery unit.
  Note
For vehicles with auxiliary heating, the plug connection for the dosing pump -V54- must be disconnected additionally.
   
–  Unplug the 5-pin plug -1- from the fuel pump.
–  Clean around the fuel filler neck.
–  Unscrew right rear wheel.
–  Remove the rear right wheelhouse liner → Body Work → Rep. gr.66.
  M20-0232
–  Unscrew screws -1- for filler neck on the body.
–  Unclip the electrical cable from the bracket -2- at the top and bottom of the filler neck.
  S20-0245
–  Disconnect vent line -1- (white) and fuel feed line -2- (black) at the connection point.
  Note
t  For vehicles with auxiliary heating, the fuel line for the dosing pump -V54- must be disconnected additionally.
t  Press in the securing ring in order to unlock the line.
–  Remove middle part of exhaust system, if necessary first separate the middle and rear part of the exhaust system → Chapter.
  S20-0163
–  Release fixing screws -2- and -4- and remove the tensioning strap.
–  Support fuel tank using the engine/gearbox jack -V.A.G 1383 A-.
–  Release fixing screws -1- and -3-.
–  Slightly lower the fuel tank.
  Note
The filler neck must be „extracted“ between structure and rear axle Lift down the fuel tank with a 2nd mechanic from engine/gearbox jack -V.A.G 1383 A-.
Install
–  Check both earth connections for corrosion, if necessary remove corrosion.
  S20-0246
–  Check fitting position of the earth lead -1-.
l  The plug -1- on the metal plate ring -2- must be placed on firmly.
l  The contact tab -4- must be hung in the fuel tank -3- and secured with the spacer bush -5-.
–  Guide the filler neck between rear axle and structure with the assistance of a 2nd mechanic. Then position the fuel tank onto the engine/gearbox jack -V.A.G 1383 A-.
Further installation occurs in reverse order. Pay attention to the following:
t  Lay the vent and fuel lines without any kinks.
t  Do not mix-up the feed line and the return-flow line (the return-flow line is blue, the feed line is black).
t  Make sure the line connections and the 5-pin plug fit tightly.
t  Check earth connection of fuel tank/body at filler neck.
t  After installing the fuel tank, check whether the lines are also clipped in place on the fuel tank.
  S20-0242

Testing fuel pump > < Removing and installing the sender for fuel gauge displayG