Fuel Tank

Fuel Tank

Special tools, testers and auxiliary items required

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

• Engine/Transmission Jack (V.A.G 1383 A)

Removing

- Read the safety precautions before starting. Refer to => [ Safety Precautions ] Safety Precautions.

- Empty the fuel tank if necessary, using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Procedures.

- Remove the rear bench seat.

- Remove the cover from the fuel delivery unit.






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






- Remove the fuel tank door unit.

- Remove the tension struts - A and B -. .






- Remove the center and rear mufflers.

- Remove the center muffler heat shield.

- Remove the right rear wheel.

- Remove right rear wheel housing liner.

- Unclip electrical wire - 1 - on the filler connection.






- Disconnect the ventilation line - 3 -.

- Remove the fuel filler tube bolts - 2 - from the body.

- Disconnect the ventilation line - 1 - (white) and vacuum line - 2 - (green) for the Leak Detection Pump (LDP) (V144) behind the fuel tank by pressing in the circlips.







The fuel system is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then release pressure by carefully disconnecting the connection.

- Disconnect vent line - 1 - (white) and fuel line - 2 - (black) at connecting point.






• Press in the securing ring to disengage the lines.

• The vacuum line (green) for the LDP must also be disconnected.

- Remove the tensioning strap bolts - arrows - and straps. Support the fuel tank using the (V.A.G 1383 A) while doing so






- Carefully lower the fuel tank.

Installing

Install in reverse order of removal. When doing this note the following:

• To mount the fuel tank straps, only bolts with loose washers may be used. If other bolts are used, the straps could twist when the bolts are tightened.

• Make sure vent and fuel lines are not kinked.

• Do not interchange supply and return line (return line blue, supply line black).

• Pull on the line connections to make sure they are securely fastened.

• Check the Ground (GND) connection for the fuel tank/chassis at the filler tube.

- Install the tension struts. .

Tightening Specifications






1) Replace