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-/gearbox jack -V.A.G 1383/A- Removing fuel tank –  Note safety precautions before beginning work → Chapter. –  First check whether a coded radio is fitted. If so, obtain anti-theft coding.   Note Before disconnecting battery, open fuel filler flap and, if applicable, take wheel lock adapter out of luggage compartment. –  Disconnect earth strap at battery with ignition switched off → Electrical system; Rep. Gr.27. If necessary, empty fuel tank using fuel extractor -VAS 5190- → Chapter. –  Remove seat bench → General body repairs, interior; Rep. Gr.72.

–  Remove cover -1- from fuel delivery unit.

–  Pull 5-pin connector -1- off flange. –  Remove right rear wheel. –  Remove rear right wheel housing liner → General body repairs, exterior; Rep. Gr.66. –  Unscrew tank flap unit securing bolt and remove tank flap unit → General body repairs, exterior; Rep. Gr.55.

–  Unbolt filler pipe from body -arrows-. –  Unclip electrical wiring from filler pipe. –  Remove middle and rear silencers. –  Remove heat shields from middle and rear silencers.   WARNING The fuel supply line is under pressure! Wear protective glasses and clothing 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.   Note Press in safety ring to release fuel lines.

–  Disconnect breather hose -1- (white) and fuel line -2- (black) at connecting point.

–  Remove securing strap bolt and securing strap. When doing this, support fuel tank with engine-/gearbox jack -V.A.G 1383/A-. –  Lower fuel tank. Installing fuel tank Installation is performed in the reverse sequence. In the process, note the following: t  Install breather and fuel lines free of kinks. t  Do not interchange supply and return hose (return hose blue or with blue markings, supply hose black). t  Ensure that fuel line connections are tight. t  Check earth connection between tank and body of filler neck. t  If fuel delivery unit was renewed, adapt engine control unit to fuel pump → Vehicle diagnosis, testing and information system VAS 5051.