Removing and installing fuel tank, four-wheel drive, engine codes BJB, BLS, BSU — VW
Removing and installing fuel tank, four-wheel drive, engine codes BJB, BLS, BSU on VW: factory workshop procedure for engines BDJ, BJB, BLS, BMM.
Workshop procedure for VW — the factory write-up, straight from real workshop data.
📋 Procedure
Removing and installing fuel tank, four-wheel drive, engine codes BJB, BLS, BSU
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Removing:
Note
Note safety precautions before starting installation work
Chapter
.
Observe rules for cleanliness
Chapter
.
Assembly overview - fuel tank, vehicles with four-wheel drive
Chapter
.
When lowering fuel tank, guide it carefully to prevent damage.
Draining fuel tank
Chapter
Remove left rear wheel.
Remove tunnel bridge from underbody
Rep. gr.
66
Mouldings/trims/extensions/trim panels; Assembly overview - tunnel bridge
.
Unbolt both shock absorbers on rear axle
arrow
.
Remove carrier plate
1
.
Unscrew securing bolts
arrows
and lower fuel tank as far as propshaft.
Pull connectors off flanges.
WARNING
The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!
Wear eye and hand protection when performing any type of repair work on the fuel system!
Pull fuel lines off flange.
Note
Press in securing ring to release supply and return lines.
WARNING
Fuel tank is tilted to side during further work. To do this, fuel tank must be completely drained.
2nd chamber still full of fuel:
Open locking ring using
wrench
T10202
.
Lift up
fuel gauge sender 2
G169
.
Insert suction hose of
fuel extractor
VAS 5190
as far as possible into fuel tank. Extract fuel.
Fuel tank completely drained:
Pull off breather line on fuel tank and unclip from fuel tank.
Loosen clamp
2
and pull connecting hose
1
off fuel tank.
Lower rear axle by approx. 20 mm.
With fuel tank in position shown remove towards left-hand side.
Installing:
Install in reverse order. Observe the following:
Install breather and fuel lines free of kinks.
Ensure that fuel hose connections are tight.
Do not interchange supply line and return line (return line blue or with blue marking, supply line black).
Specified torques:
Specified torques for fuel tank
Chapter
.
Component
Nm
Tunnel bridge to underbody
25
Shock absorber to rear axle
Rep. gr.
42
Wheel bolt to wheel hub
120
TorqFix answers live for your specific car — tell it the engine code and it serves the matching sequence, torque figures and wiring for that exact variant.
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Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.