Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ V.A.G 1331 Torque wrench (5...50 Nm)

• ◆ V.A.G 1383 A Engine/gearbox jack

Removing

• ‒ Note safety precautions before starting work
  

Note:

Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected. Obtain radio code first if necessary.

• ‒ With the ignition switched off disconnect battery earth strap.
• ‒ Fold rear seat bench forwards.
• ‒ Remove cover under bench seat.

• ‒ → Pull fuel return flow pipe -1- (blue) and fuel supply pipe -2- off flange.

Note:

Press buttons on hose couplings -arrows- to do this.

• ‒ Pull off connector -3-.
• ‒ Open fuel flap.
• ‒ Drain fuel tank, clean fuel filler neck and surrounding area.
• ‒ Unhook front and rear silencers and if necessary tie to body with wire.
• ‒ Remove rear right wheel.
• ‒ Detach filler pipe from body.
• ‒ Take filler cap off filler neck and detach filler neck from cup.
• ‒ Remove tensioning strap. When doing this support fuel tank with engine/gearbox jack V.A.G 1383 A.
• ‒ Remove filler pipe.
• ‒ Take out fuel tank together with heat shield.

Installing

Install in reverse order but note following:

• ◆ Route breather hose kink free.
• ◆ Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).
• ◆ Clip supply and return pipe onto fuel tank.

→ Connections for return flow pipe -1- (blue or with a blue mark) and black supply pipe -2- are marked on the fuel gauge sender flange by arrows.