Removing and installing fuel tank

Special tools and workshop equipment required

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

• Engine and gearbox jack - V.A.G 1383 A-

1.6.1 Removing

• Note safety precautions before beginning work ⇒ 1.2 Safety regulations for working on fuel supply.
• First check whether a coded radio is fitted. If so, obtain antitheft code.
• With the ignition switched off, disconnect battery earth strap.
• Unscrew securing bolts and remove tank flap unit.
• Drain fuel tank and clean fuel filler neck and surrounding area.
• Fold rear seat bench forwards.
• Remove cover from fuel delivery unit.
• Pull 4-pin connector off flange.
• Remove rear right wheel.
• Remove rear right wheel housing liner ⇒ General body repairs, exterior; Rep. gr. 66; Removing and installing wheel housing liner.
• Remove activated charcoal filter.
• Unbolt filler neck from body.
• Unscrew all rear exhaust system retainers from body. Then support lowered exhaust system on body with wire.
• Remove rear axle: ⇒ Running gear, axles, steering; Rep. gr. 42; Repairing rear axle; Removing and installing rear axle.

• Disconnect supply line -1- (black) and breather line -2- (white) at connecting point.
• Unscrew securing strap and securing bolts. When doing this, support fuel tank with engine and gearbox jack -V.A.G 1383 A-.
• Lower fuel tank.

1.6.2 Installing

Install in reverse order of removal. During this step, observe the following:

• Install breather and fuel hoses free of kinks.
• Ensure fuel hoses are seated correctly.
• Do not interchange supply and return lines (return line blue or with blue markings, supply line black).