Fuel Tank

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Special tools and workshop equipment required

Torque Wrench (5-50 Nm) V.A.G 1331

Removing

The fuel tank may be a maximum of 1/4 full.

NOTE:

Drain the fuel tank as necessary using the fuel extracting device VAS 5190. Refer to FUEL TANK, DRAINING .

Read the safety precautions before starting. Refer to SAFETY PRECAUTIONS .

Pay attention to the rules of cleanliness. Refer to CLEAN WORKING CONDITIONS .

-- Turn off the ignition and all electric consumers and remove the key.

-- Open the fuel filler flap and remove the fuel filler cap.

-- Remove the bolt for the fuel flap unit and remove the fuel flap unit. Refer to Removal and Installation .

-- Remove the rear bench seat. Refer to Removal and Installation .

-- Remove the cover -1- from the fuel delivery unit. The arrow -2- points in the direction of travel.

Fig 1: Removing Cover From Fuel Delivery Unit

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-- Disconnect the connector -arrow- from the fuel delivery unit.

Fig 2: Fuel Pump Control Module Connector

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-- Remove the right rear wheel housing liner. Refer to Removal and Installation .

-- Disconnect the connectors -1 and 2-.

Fig 3: Disconnecting Fuel Filler Tube Connections

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-- Remove the fuel filler pipe bolts -arrows-.

-- Unclip the Antilock Brake System (ABS) line -A- from the bracket -arrows-.

Fig 4: Unclipping ABS Line From Bracket

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-- Remove the center muffler. It may be necessary to separate the center and rear mufflers beforehand. Refer to MIDDLE AND REAR MUFFLERS, SEPARATING AND CONNECTING .

WARNING:

The fuel system is under pressure!

Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

-- Disconnect the ventilation line from the Evaporative Emission (EVAP) canister at the connection behind the fuel tank.

-- Disconnect the white vent line -1-, black supply line -2- and green vacuum line for the leak detection pump -V144- -3- at the connecting point.

Fig 5: Separating White Vent Line, Black Supply Line And Green Vacuum Line For Leak Detection Pump (LDP) V144 At Connecting Point

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NOTE:

Press in the securing rings to disengage the lines.

For the continuing work sequence, a second mechanic is needed to support the fuel tank.

-- Remove the tensioning strap bolts, the tank side bolts -arrows-, and the straps.

Fig 6: Identifying Fuel Tank Bolts

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-- Remove the fuel tank.

Installing

Installation is performed in the reverse order of removal. When doing this note the following:

Only use bolts with loose washers to secure the fuel tank straps. The straps could twist when the bolts are tightened if other bolts are used.
Make sure the vent and fuel lines are not kinked.
Do not interchange the supply and return lines (the supply line is black, the return line is blue).
Make sure the connector and the lines are secure. Pull on them if necessary.
Check the fuel tank/body ground connection on the filler tube.
After installing the fuel tank, check to be sure the lines are still clipped onto the fuel tank.

-- Bleed the fuel supply system. Refer to FUEL SYSTEM, BLEEDING .

Tightening Specifications

Component		Nm
Fuel filler pipe to body - M6		11
Fuel tank to underbody - M8 Replace bolts		26