B. Replacement of Fuel Tank

- With vehicle still on the hoist, attach memory saver for radio codes then remove ground strap from battery

- Remove rear seat (Cabriolet) or trunk cover (Scirocco)





- Remove fuel sending unit access cover





- Clamp fuel hoses and disconnect; mark hoses to ensure correct reinstallation.

- Remove electrical connection from sending unit.

- Remove sending unit, including fuel feed pump.

- Remove remaining fuel from tank through sending unit opening fuel storage cart.

- Lift vehicle completely.





- Disconnect filler neck from fuel tank by loosening clamps and connecting hose

- Detach fuel pump bracket from body and lower pump assembly

- Disconnect brake hoses at rear wheels on both sides.

- Detach rear axle from body on both sides, swing it down and let hang carefully on hand brake cable guides.

- Support tank with tool OTC 1785A or similar support; detach tank from body and lower carefully.

- Remove fuel tank and place in safe area until fumes can be neutralized.





- Attach new heat shield, part number 133 201 281, to new tank unit, part number 133 201 072. (New tank has new fuel level sending unit and fuel pump already installed)

- Use all sound dampening felt strips from kit, part number 155 298 121 and glue to new tank at same locations as old tank.

- Install new fuel tank unit and perform all connections in reverse order - use new clamps for all hose connections





- Remove gravity valve, replace with new valve, part number 133 201 753. Use two (2) new hose clamps, part number N 024 528.1.

- Reinstall wheelhousing cover and wheel

- Bleed brakes

- Coat underside of new tank with underbody sealant, part number D 003 500.

- Lower vehicle completely.

- Tighten right rear wheel.





- Refill tank from cart.

- Reconnect battery

- Assure function of fuel gauge and check correct clock time.

- Start engine, check all fuel and vacuum line connections

- Reinstall tank access cover and rear seat/trunk cover.

- Check function of vehicle