Fuel Tank With Attachments
MPI Engines
Fuel Tank with Attachments
Special tools, testers and auxiliary items required
• Engine/Transmission Jack (V.A.G 1383 A)
• Support (T10031)
Removing
Observe safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.
Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.
• For removal, fuel tank must be empty for weight reasons. Empty fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Procedures.
- Release the fuel tank flap.
Observe measures when connecting battery.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
- Remove the luggage compartment floor mat.
- Unbolt cover for right locking flange - arrows -.
- Disconnect vent line - arrow - by pressing releases.
Before removing the subframe bolts, secure the vehicle against tipping over (for example load the luggage compartment with approximately 50 kg).
- Remove rear axle.
- Remove right rear wheel housing liner.
- Disconnect Ground (GND) wire - 3 - from fuel filler tube.
- Disconnect electrical connector - 1 - for Fuel Tank Lock Switch (F314).
- Disconnect vent line - 5 - from fuel filler tube.
- Remove the bolts - 2 - and - 4 - for the fuel filler tube.
- Make sure the driveshaft is secured against falling down.
• The driveshaft must be set on a wooden block - 1 - and be secured with wire or cable tie - arrow -
• Make sure that the driveshaft is angled slightly downward so that the fuel tank can later be guided over this and out during removal.
• The max. allowable angle of the driveshaft must not exceed 8°.
- Remove heat shield - arrows - for driveshaft.
• The heat shield is also clipped in at the top to the vent line.
- Remove left cover - 1 - from bottom of vehicle floor panel.
- Remove the right cover - 1 - from bottom of vehicle floor panel.
- Disconnect electrical harness connectors:
2 To fuel pumps
3 To fuel gauge sensors
- Separate the fuel lines by pressing the release buttons:
1 Fuel return line
4 Fuel supply line
- Disconnect the right rear vent line - arrow - on fuel tank by pressing release button.
- The brake calipers, that were previously hung on the fuel tank brackets when the rear axle was removed, must now be attached to the struts with wire - arrow -.
- Place the Engine/Transmission Jack (V.A.G 1383 A) with Support (T10031) (without threaded rods) under the fuel tank for support.
- Support the fuel tank with the Engine/Transmission Jack (V.A.G 1383 A) and Support (T10031).
- A second technician must also support the fuel tank by hand at the rear edge.
For weight reasons, fuel tank must be empty for removal.
- Remove bolts - 1 to 6 - and if necessary, pivot the fuel tank brackets forward.
- Lower the fuel tank toward the rear slightly so that the fuel filler tube can be guided out of the body.
- Lower the fuel tank with the Engine/Transmission Jack (V.A.G 1383 A), thereby guiding it by hand.
• To improve clarity, the fuel tank is shown without the Engine/Transmission Jack.
Installing
• Tightening specifications. Refer to => [ Fuel Tank with Attachments Assembly Overview ] MPI Engines Overview.
- Make sure the fuel lines and wiring harnesses to fuel pumps and fuel level sensor are clipped on brackets - 1 - on fuel tank.
- When installing a new fuel tank, paste the backing pieces - 2 - onto the fuel tank, as shown in the illustration.
- Position the fuel tank with mounting straps and brackets to vehicle floor using the Engine/Transmission Jack (V.A.G 1383 A) and Support (T10031).
- Make sure the fuel tank is positioned so that the filler tube can be correctly guided into the opening of the body.
- Fasten the fuel tank to the fastening points - 1 -, - 2 -, - 5 -, - 6 - first, and then to - 3 - and - 4 -.
- Make sure that the spacer of the securing straps is seated directly below the seam of the fuel tank - arrow -.
- Fasten the fuel filler tube with using bolts - 2 - and - 4 -.
- Push the vent line - 5 - on until it engages audibly.
- Connect the electrical connector - 1 - for Fuel Tank Lock Switch (F314).
- Check if the Ground (GND) wiring - 3 - and the contact show signs of oxidation. If necessary, remove.
After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter:
• Specified value: approximately 0 Ω.
The rest of the installation is in reverse order of removal, note the following:
• Replace seals and gaskets when performing repair work.
• Secure all hose connections with hose clamps appropriate for the model.
- Install rear axle.
- Install right rear wheel housing liner.
- Install rear section of exhaust system.
- Connect battery. Observe safety precautions after connecting battery.