Fuel Filler Neck: Service and Repair

Observe safety precautions.
Observe rules for cleanliness

Removing
- Obtain radio code on vehicles with coded radio/integrated radio and navigation system.
- With ignition switched off, disconnect battery Ground (GND) strap.


WARNING!
When removing the fuel filler neck with expansion tank, the fuel tank should not be fuller than 3/4.


- Drain fuel tank, refer to "Fuel Tank, Draining" Service and Repair
- Remove right rear wheel.
- Remove right rear wheel housing liner:
- Clean area around fuel filler neck.
- Open fuel filler cap, unclip rubber cup (around filler neck).
- Press rubber cup toward inside.







- Loosen hose clamps -3- at upper connection hose between expansion tank and fuel filler hose -1-
- Push upper connection hose from expansion tank over fuel filler hose -1-.
- Mark vent hoses -2-, -4-, -5- and -6- for installation.
- Disconnect vent hoses -2-, -4-, -5- and -6- from lines







- Unscrew 3 screws -arrows-.
- Carefully lower expansion tank slightly.







- Disconnect Ground (GND) cable -2- at metal ring (Ground clamp) of fuel filler neck.
- Remove filler neck with expansion tank.
- Unclip over flow hose.

Installing
Installation occurs in reverse order, observe the following:


NOTE:
- Make sure that ventilation hoses are correctly installed (not kinked)
- For the installation of band clamps it is recommended to use the VAG1921 pliers.


CAUTION!
Always refer to latest parts catalog to ensure that you use original equipment fuel hose clamps.







- Ensure that electrical connector -2- for Ground (GND) connection is properly seated on metal ring (Ground clamp) -1- on fuel filler neck.


CAUTION!
After installing the expansion tank, use ohmmeter to check the electrical connection between metal (Ground clamp) ring on the fuel filler neck and bare metal part (Ground) on Body.


- Specification: approx. 0 ohm

If the specification is not attained:
- Check wiring.
- Check that Ground (GND) connection is properly connected to the Ground (GND) point next to the battery.


CAUTION!
It is important to ensure that the Ground (GND) connection is secured at the threaded terminal and the connector is properly seated at the fuel filler neck.


Connect battery and enter anti-theft code on vehicles with coded radio/radio and navigation system

See Radio operating instructions

- Close windows fully to top using electric window switches.
- Then operate all electric window switches again for at least one second in the "Close" position to activate the automatic up and down function.
- Set clock to correct time.

Tightening torque

Component Nm
Fuel filler neck with expansion
tank on body 5