Fuel Tank, Removing and Installing
Fuel Tank Assembly, Removing And Installing
WARNING!
Fire hazard! Do NOT have anything in the area that can ignite gasoline!
Required special tools, testing equipment and auxiliary equipment
- VAG1359/2 Universal holder
- VAG1383 A Engine and transmission jack
Removing
CAUTION!
Obtain the radio Anti-theft code from the customer before disconnecting the Battery Ground strap.
- Disconnect Battery Ground strap.
- First ensure that ignition is switched OFF.
- Open fuel tank cover briefly and close again.
- If necessary, drain fuel tank using fuel cart.
WARNING!
Empty the fuel tank before removing it! If it is not empty, the weight and sloshing fuel could lead to injury, component damage or possible fuel spillage.
NOTE: For weight reasons, fuel tank must be empty before removing.
- Remove rear axle.
- Remove connector flange cover under luggage compartment trim.
- Unlatch and disconnect 4-pin harness connector -1-.
NOTE: Return line -2- and supply line -3- remain connected.
- Clean area around fuel filler neck.
- With fuel filler cap removed, pry out clamp ring on rubber seal (around filler neck).
- Push rubber seal through and toward the inside.
- Remove right rear wheel house liner.
- Remove screw -1- for fuel filler neck, Ground connection -2- and protective plate -3- under the wheel house shell.
WARNING!
Fuel system is under pressure! Before opening, place clean cloths around the connections to be opened. Carefully loosen the connections to relieve pressure.
- From bottom of vehicle, mark supply line -1-, return line -3- and bleed line to EVAP canister and disconnect -2-.
- Remove the EVAP canister cover near bottom of spare wheel well.
- Loosen hose connections -1- and -2- on bleed lines.
- Unclip line from bracket -arrow-.
- Place VAG1383A engine and transmission jack under the fuel tank for support.
- Mark installed position of the clamp bands.
- Disconnect clamp bands and carrier plate -arrows-.
- Lower fuel tank.
NOTE: Ensure that the bleed line stays clipped to the fuel tank during fuel tank removal.
Installing
Installation is performed in the reverse order of removal, during installation note the following:
CAUTION!
Always refer to the latest parts catalog to ensure that you use original equipment fuel hose clamps.
NOTE:
- Secure all hose connections using spring clamps:
- VAG1921 Hose clamp pliers are recommended for installing spring clamps.
- Always replace sealing rings and gaskets during installation work.
- Ensure that Ground connection -arrow- connects to metal ring on filler neck.
- Check Ground wire routing.
- Loosely fasten clamp bands and carrier plate to fuel tank.
- Position fuel tank on floor pan complete with clamp bands and carrier plate using VAG1383 A engine transmission jack.
- Before threading in mounting screw -1- ensure tight fit (chamfer) of screw eye -2- on protective plate Ground connection -3- for fuel filler neck.
CAUTION!
Ensure that Ground connection is surrounded with a protective shield and connector on fuel filler neck is securely attached.
- Screw the clamp bands and carrier plate tight -arrows-.
- Tighten plastic nuts on clamp bands and carrier plate.
- Connect lines according to markings:
1 - Supply line
2 - Bleed line to EVAP canister
3 - Return line
- Re-connect fuel pump and sender for fuel gauge harness connectors.
CAUTION!
After installation, check for continuity between Ground clamp on filler neck and chassis Ground.
- Specification: approximately 0 Ohms.
- Connect Ground strap to Battery with ignition OFF.
- After connecting Battery, input radio anti-theft code
- Run door windows up to the stop using window switches.
- Operate all window switches again for at least 1 second in "closed" position to activate automatic up/down.
- Re-set the clock.
Tightening torques
Component Nm
Clamp bands and/or carrier plate (for fuel tank) on chassis 25 Nm
Clamp bands on fuel tank 2 Nm
Carrier plate on fuel tank 2 Nm
Cover on spare wheel well 10 Nm