Fuel tank, removing and installing

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Special tools, testers and auxiliary items required

Fig 1: Special Tool - Torque Wrench V.A.G 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Torque wrench V.A.G 1331

Fig 2: Engine & Transmission Jack VAG 1383 A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine/transmission jack V.A.G 1383 A

Removing

Read safety precautions before beginning work refer to Safety precautions when working on fuel supply system .
First, check whether a coded radio is installed. If necessary, obtain the anti-theft coding.
With ignition switched off disconnect battery Ground (GND) strap.
Open fuel tank flap.

Remove right rear wheel housing liner, refer to REAR WHEEL-HOUSING LINER .
Remove rear axle, refer to REAR AXLE, REMOVING AND INSTALLING or REAR AXLE WITH FOUR WHEEL DRIVE, OVERVIEW .
Drain fuel tank and clean fuel filler tube and surrounding area.
Remove mounting bolt and remove fuel flap unit with rubber gasket.

Remove securing bolt on filler neck.
Fold rear seat bench forward.
Remove cover plate from fuel gauge sensor and disconnect connector.
Remove covers under fuel tank.

CAUTION: Fuel supply lines are under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

Fig 3: Fuel Supply Hose, Return Hose & Breather Hose

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect return line - 2 - (blue), supply line - 1 - (black) and breather line - 3 - (white) at their connection points.

NOTE:

Press buttons together on hose connections to do this.

Remove tensioning strap. While doing so, support fuel tank using engine/transmission jack V.A.G 1383 A
Lower fuel tank.

Installing

Installation is in reverse order of removal, note the following:

Make sure ventilation and fuel lines are not kinked when installed.
Route fuel hoses kink-free.
Ensure fuel hoses are seated securely.
Secure fuel hoses with spring-type clamps.

Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).

NOTE:

After installing fuel tank, check that the supply, return and breather lines are still clipped onto the fuel tank.

Perform "Procedure after interrupting voltage supply", refer to PROCEDURE AFTER VOLTAGE SUPPLY OPEN CIRCUIT .