Removing and installing fuel tank with its attachments — VW

Removing and installing fuel tank with its attachments on VW: factory workshop procedure for engines 1F, 1Z, 2E, AAC. Full factory text, tools and checks.

Workshop procedure for VW — the factory write-up, straight from real workshop data.

factory workshop text 36 engine codes engine codes merged from 19 documented variants

🔧 Engine codes this applies to

1F 1Z 2E AAC AAF AAZ ABD ABF ABU ACU ADY ADZ AEA AEE AEF AET AEX AFH AFN AFT AFV AFX AGD AGY AHG AHU AKU AKV ALM ANX API APQ ASX ASY AVG AVT

📋 Procedure

ℹ️ Torque figures below come verbatim from workshop data — always cross-check against your vehicle's factory manual before final tightening.

AEX AKV APQ ANX ALM
Fuel system Polo Classic, Polo Estate

Fuel system Caddy

=> Page
20-7

Cap
Retaining ring
Tank flap unit
Removing and installing

=> General body repairs; Repair group 55; fuel flap unit
General body repairs
fuel flap unit

Vent pipe
To activated charcoal filter
=>Page
20-31
, Item
8

Gravity/overflow valve
To remove, release locking lug and unclip valve upwards out of filler neck
Check valve for through-flow
valve vertical: open,
valve tilted 90 °: closed

Earth connection
4 Nm
Fuel gauge sender
Return hose/line
Blue or with blue marking
To fuel manifold

=> Repair group 24; mixture preparation, injection
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine)
mixture preparation, injection

Union nut, 75 Nm
Remove and install with 3217

Flange
Note fitting position on fuel tank => Fig.
1

Corrugated tube
Must not contact fuel tank, otherwise pump noises will be transferred

Sealing ring
Coat with fuel when installing
Renew if damaged

Fuel delivery unit
Removing and installing
=> Page
20-15
Checking fuel pump
=> Page
20-17

Note:

After completing work on fuel delivery unit or fuel gauge sender ensure that the corrugated tubing between delivery unit and flange does not contact the fuel tank (transfer of pump noises).

Fuel filter
Fitting position: Arrow points in direction of flow

Supply pipe
Black
From fuel manifold

=> Repair group 24; mixture preparation, injection
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine)
mixture preparation, injection

1F? This is the factory text for the model family — variants differ. Check it against your exact car. Check my car — free →

3 Nm
Fuel tank
Removing and installing
=> Page
20-26
Press clamping washer from heat shield tightly onto pins on vehicle floor

25 Nm
Sealing boot
After installing filler pipes fit over fuel tank connections, having turned boot inside out

Filler pipes
With non-return valve

Vent valve
Checking =>Fig.
2
To remove pull locking latch lightly to inside -arrow- and pull valve out

O-ring
Renew if damaged

Cup
For filler pipes

Fuel system Caddy

Cap
Retaining ring
Tank flap unit
Removing and installing

=> General body repairs; Repair group 55; fuel flap unit
General body repairs
fuel flap unit

Vent pipe
To activated charcoal filter
=>Page
20-31
, Item
8

Gravity/overflow valve
To remove, release locking lug and unclip valve upwards out of filler neck
Check valve for through-flow
valve vertical: open,
valve tilted 90 °: closed

Earth connection

4 Nm
Fuel gauge sender
Return hose/line
Blue or with blue marking
From fuel manifold

=> Repair group 24; mixture preparation, injection
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine)
mixture preparation, injection

Union nut, 75 Nm
Remove and install with 3217

Flange
Note fitting position on fuel tank => Fig.
1

Corrugated tube
Must not contact fuel tank, otherwise pump noises will be transferred

Sealing ring
Coat with fuel when installing
Renew if damaged

Fuel delivery unit
Removing and installing
=> Page
20-15
Checking fuel pump
=> Page
20-17

Note:

After completing work on fuel delivery unit or fuel gauge sender ensure that the corrugated tubing between delivery unit and flange does not contact the fuel tank (transfer of pump noises).

Fuel filter
Fitting position: Arrow points in direction of flow

Supply pipe
Black
To fuel manifold

=> Repair group 24; mixture preparation, injection
4-Cyl. injection engine, Mechanics (1.4 and 1.6 l engine)
mixture preparation, injection

3 Nm

Fuel tank
Removing and installing
=> Page
20-26

Heat shield
Press clamping washer from heat shield tightly onto pins on vehicle floor

25 Nm
Sealing boot
After installing filler pipes fit over fuel tank connections, having turned boot inside out

Filler neck
With non-return valve

Vent valve
Checking =>Fig.
2
To remove pull locking latch lightly to inside -arrow- and pull valve out

O-ring
Renew if damaged

Cup
For filler pipes

Fig. 1
Installation position of fuel delivery unit flange

Marking on the flange must align with marking on the fuel tank.

Fig. 2
Checking vent valve

Lever in rest position: Closed

Lever pushed in direction of arrow: Open

Fig. 3
Removing and installing accelerator pedal

To remove the accelerator pedal, press the accelerator pedal shaft locking device carefully out of the drilling -arrow-, then turn the shaft with a 6 mm hexagon key until it can be pulled out.

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Other VW procedures

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

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Workshop data on this page last updated 20 Sep 2026.