Fuel Tank

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Removing

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

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

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

-- Remove the cover -1- and the fuel pump control module -J538- -2- from the fuel delivery unit.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

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-- Disconnect the 5 pin connector -arrow- from the flange.

Fig 2: Identifying Fuel Delivery Unit Connector

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-- Remove the right rear wheel.

-- Remove the right rear wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

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

-- Disconnect the hoses -1 and 2-.

Fig 3: Disconnecting Hoses

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

-- Unclip the electrical wire from the filler connection.

-- Remove the center and rear mufflers.

-- Remove the heat shield from the center and rear mufflers.

WARNING:

Fuel system is under pressure!

Always wear protective eye-wear 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 vent line -1- (white) and fuel line -2- (black) at the connecting point.

Fig 4: Disconnecting Vent Line (White) And Supply Line (Black) At Connecting Point

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NOTE:

Press the locking ring to release the lines.

The vacuum line (green) for the leak detection pump -V144- must also be disconnected.

-- Remove the tensioning strap bolts and straps. Support the fuel tank using the engine/transmission jack V.A.G 1383 A while doing so

Fig 5: Removing Fuel Tank Bolts

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-- Carefully lower the fuel tank.

Installing

Install in 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 (return line is blue or has a blue mark, supply line is black).
Pull on the line connections to make sure they are secure.
Check the fuel tank/body ground connection on the filler tube.
If the fuel delivery unit was replaced, then it is necessary to adapt the Engine Control Module (ECM) to the fuel pump. Refer to "Guided Functions" in the vehicle diagnosis, testing and information system VAS 5051

Tightening Specifications

Component

Fuel tank to chassis - bolts M6

Fuel tank to chassis - bolts M8

25 ⁽¹⁾

⁽¹⁾

replace