Volkswagen Workshop Service and Repair Manuals

(55 litre fuel tank)

Removing

• ‒ Note rules for cleanliness
• ‒ Detach earth strap at battery with ignition switched off.

Note:

If applicable, first interrogate the radio anti-theft coding.

• ‒ Remove bottom cover in boot.
• ‒ Pull connector as well as supply and return line off flange.
• ‒ Empty tank.

• ‒ Remove cover in rear right wheel house.
• ‒ → Pull large breather pipe -3- off the filler neck.
• ‒ Pull off gravity valve downwards (lines -1- and -2- remain connected).

• ‒ → Detach brake hoses on left and right at rear axle -black arrow-.
• ‒ Detach rear axle from body on both sides -white arrows-, swing it down and let it hang on the handbrake cable guides.
• ‒ Unhook support loops at exhaust system.
• ‒ Pull hose off filler neck at fuel tank.
• ‒ Support fuel tank with V.A.G 1383, unscrew from body and set down carefully.
• ‒ Pull plug off fuel gauge sender.
• ‒ Pull breather pipes off fuel tank.
• ‒ Remove fuel tank.

Installing

• ‒ Installation is performed in reverse order.

=> Repair Group 47; Bleeding brake system

Note:

• ◆ On connecting large and small breather pipe, turn clamps such that they have no contact with body.
• ◆ If a new fuel tank is installed, foam strips are to be bonded on at the same locations as on the tank removed.
• ◆ Vehicles with a catalyst which run on unleaded fuel have a constriction in the filler neck as well as a spring-loaded flap.