Removing and installing fuel tank, engine codes AXA, BDL, BKK — VW

Removing and installing fuel tank, engine codes AXA, BDL, BKK
WARNING
Risk of explosion of fuel tank. If a new or completely empty fuel tank has been installed, it must be filled immediately with at least 5 litres of fuel. The fuel pump must not be allowed to run when the fuel tank is empty.
Special tools and workshop equipment required
Union nut tool
3217
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
Fuel extractor
VAS 5190
Prerequisites
Fuses SD14 and SD30
arrows
must be removed from their sockets.
Note safety precautions before starting installation work
Chapter
.
Observe rules for cleanliness
Chapter
.
Removing:
Note
Fuel tank must be drained. Use the
fuel extractor
VAS 5190
to do this.
First relieve fuel pressure as follows:
WARNING
The fuel line is under pressure.
Risk of injury to eyes and skin from fuel.
Wear eye protection and protective clothing to avoid eye injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully opening the connection point.
Pull off supply hose
3
and return hose
2
(with blue mark). Collect escaping fuel with a cleaning cloth.
Note
Press in buttons on hose couplings to do this.
Once the fuel pressure has been relieved:
Reconnect fuel hose again, hose couplings must engage audibly when reconnecting.
Open fuel filler flap and clean area around filler cap.
Remove filler cap and unbolt securing bolt of retaining strap.
Remove securing bolt
Item
of filler neck.
Raise vehicle.
First unbolt cover with heat shield
arrows
.
Now unbolt side cover from fuel tank.
Note
There is still fuel in the fuel lines!
Place cleaning cloths around separating point.
Fuel supply line on filter outlet
4
, disconnect blue fuel return line
2
and fuel supply line
1
on vehicles with an auxiliary/supplementary heater.
Pull white breather line off activated charcoal filter
3
.
Note
Press in buttons on hose couplings to do this.
Remove securing straps. When doing this, support fuel tank with
engine and gearbox jack
V.A.G 1383 A
.
Lower
engine and gearbox jack
V.A.G 1383 A
just sufficiently to allow connector to be pulled off flange of fuel delivery unit
1
. Lines
2
,
3
and
4
remain connected.
Lower fuel tank.
Installing:
WARNING
Risk of explosion of fuel tank. If a new or completely empty fuel tank has been installed, it must be filled immediately with at least 5 litres of fuel. The fuel pump must not be allowed to run when the fuel tank is empty.
Installation is carried out in the reverse order. When installing, note the following:
Connector and fuel lines must be reconnected securely to fuel delivery unit flange.
Connections for breather and fuel lines must engage audibly when joined.
Fuel lines must be clipped onto fuel tank.
Ensure that fuel hose connections are tight.
Specified torques
Chapter
“
Assembly overview - fuel tank
”