Fuel Tank With Attachments, Removing and Installing
Fuel Tank With Attachments, Removing And Installing
Special tools and equipment
- VAG 1383 A and VAG 1359/2
- The fuel tank must be empty when it is removed from the vehicle in order to reduce weight. Drain fuel tank if necessary.
WARNING: Observe safety precautions when disconnecting the battery.
- With ignition switched off disconnect battery ground strap.
- Open fuel filler cap briefly, then close it again.
Sedan:
- Detach trim in luggage compartment.
- Fold down right rear seat backrest if necessary.
Avant:
- Remove 1/3 backrest, left.
- Remove left side trim of luggage compartment and protective pan.
All models:
- Unscrew cover -arrows-.
- Disconnect ventilation pipe -1-. To do so, press unlocking ring -2- approx. 2 mm in direction of arrow -A- and disconnect ventilation pipe (arrow B).
- Remove rear seat bench.
- Detach cover for flange (left and right side) -arrows-.
- Carefully disengage and remove electrical harness connector -1- (right side of vehicle).
- Disconnect electrical harness connector -2-.
- Carefully disengage and remove electrical harness connector (arrow) (left side of vehicle).
- Remove right-rear wheel.
- Remove right-rear right wheel housing liner.
- Clean area around tank filler neck.
- Pry out clamping ring -arrow- in rubber cup (on filler neck).
NOTE: Do not remove filler cap.
- Press rubber cup through to the inside.
- Remove rear section of exhaust system.
- Remove propshaft.
CAUTION: Secure vehicle against tipping over before LOOSENING the subframe bolts (e.g. load trunk compartment with approx. 50 kg).
- Remove rear axle.
WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
- Disconnect fuel supply hose -1- from fuel filter (press release button) and catch escaping fuel.
- Disconnect ventilation pipe -2- (press release button).
- Disconnect ventilation line -2- from fuel filler neck (press release buttons).
- Remove bolt -1- for fuel filler neck.
- Remove EVAP canister cover at bottom of spare tire well (arrows).
- Disconnect ventilation lines -1- and -2-. To do so, press release ring -3- in direction of arrow -A- and pull off ventilation line (arrow -B-).
- Unclip ventilation lines at top from bracket (arrow).
- Detach heat shields -1- and -2-.
- Detach handbrake cables from the retainers marked by arrows.
- Position engine/transmission hoist VAG 1383 A below vehicle to support tank.
WARNING: The fuel tank must be empty when it is removed from the vehicle in order to reduce weight.
- Take out bolts -1 through 10-.
- Lower fuel tank with carrier plate.
Installing
Install in reverse sequence; note the following points:
NOTE: Secure all hose connections using the correct type of hose clamps (as original equipment).
- Check that supply hoses, return hoses and ventilation lines are clipped onto fuel tank.
- Check the ground wiring at both ends for traces of oxidation. Remove any traces of oxidation if necessary.
- Check position of ground connection:
- Make sure connector -4- is connected securely on metal ring -3-.
- Contact tab -1- must be hooked onto the fuel tank -5- and secured with spacer sleeve -2-.
- Position fuel tank with securing straps and carrier plate on underside of vehicle using engine/transmission jack VAG 1383 A.
- Tighten bolts -1 through.10- for securing straps and carrier plate to 23 Nm.
- Secure fuel filler neck (23 Nm).
CAUTION:
After installation, use an ohmmeter to check the electrical connection between the metal ring on the fuel filler neck and a bare metal part on the body.
- Specification: approx. 0 Ohm.
- Install rear axle.
- Install propshaft.
- Install rear part of exhaust system.
- Observe safety precautions after connecting the battery.
Tightening torques
Component Nm
Securing straps and carrier plate for fuel tank to body 23
Fuel filler neck to body 23
Cover for EVAP canister 9
Battery terminal to terminal post 6