Fuel Tank With Attachments, Removing and Installing - From 11.04

Fuel Tank With Attachments, Removing And Installing







Special tools, testers and auxiliary items required
- Engine/transmission jack V.A.G 1383 A

Removing
Observe safety precautions
Observe rules for cleanliness

CAUTION:
- For removal, fuel tank must be empty for weight reasons. Drain fuel tank if necessary. Procedure
- Observe procedures for disconnecting battery







- Push cover over battery toward right - arrow 1. and remove it upward - arrow 2.







- With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
- Open fuel filler flap briefly and then close again.

Sedan:
- Remove carpeting in luggage compartment.
- Fold forward right rear seat backrest, if necessary.

Wagon:
- Remove left 1/3 backrest.
- Remove left side luggage compartment trim and dirt tray







All models:
- Unbolt cover for locking flange in luggage compartment - arrows -.







- Separate ventilation line - 1 -. Do this by pressing the releasing ring - 2 - approx. 2 mm in direction - arrow A - and simultaneously pulling ventilation line off - arrow B -.







- Remove rear seat bench.
- Unbolt cover for locking flange, left and right - arrows -.







- Disconnect electrical harness connector - arrow - at right locking flange.







- Disconnect electrical harness connector - arrow - at left locking flange.







- Open tank flap and clean area around fuel filler tube.

NOTE: Do not remove fuel cap.

- Pry tensioning ring - arrow - out from rubber cup and press rubber cup through toward inside.







- Remove right rear wheel.
- Remove right rear wheel housing liner.
- Pull ventilation line - 2 - off from fuel filler tube by pressing release buttons.
- Remove bolts - 1 - for fuel filler tube.







- Remove EVAP canister cover at bottom of spare wheel well - arrows -







- Separate ventilation lines - 1 - and - 2 -. Do this by pressing releasing ring - 3 - in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
- Unclip ventilation lines - A - at top from bracket - arrow -.
- Remove rear part of exhaust system
- Remove drive shaft.

CAUTION: Before removing the subframe bolts, secure the vehicle against falling over (e.g. load the luggage compartment with approx. 50 kg).

- Remove rear axle.







- Remove heat shields - 1 - and - 2 -.







- Disconnect parking brake cables at positions indicated by - arrows

CAUTION: The fuel system is under pressure. Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.







- Separate fuel line - 2 - and ventilation line - 1 - at right front from fuel tank, by pressing release buttons.







- Place engine/transmission jack V.A.G 1383 A under fuel tank for support.


CAUTION: For weight reasons, fuel tank must be empty for removal.


- Remove bolts - 1 through 10 -.
- Lower fuel tank using engine/transmission jack V.A.G 1383 A.







Installing
Installation is in reverse order of removal. Note the following:
- Make sure fuel and ventilation lines are properly clipped to fuel tank.
- Check if the Ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
- Check installation position of Ground (GND) connection:

- Connector - 4. must be securely attached to metal ring - 3 -.
- Contact - 1 - must be attached into fuel tank - 5. and be secured with spacer bushing - 2 -.







- Position fuel tank with mounting straps and carrier plate to vehicle floor using engine/transmission jack V.A.G 1383 A.
- Make sure fuel tank is positioned so that the filler tube can be correctly guided into opening of body.
- Fasten mounting straps and carrier plate - 1 through 10 -.
- Fasten fuel filler tube.

CAUTION: After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter:
- Specification: approx. 0 Ohm.

- Install rear axle.
- Install drive shaft.
- Install rear part of exhaust system.
- Install right rear wheel housing liner, thereby fastening the bolt for fuel filler tube.
- Connect battery. Observe safety precautions after connecting battery.

Torque specifications

Component Nm
Mounting straps and carrier 23
plate for fuel tank to body
Fuel filler tube to body 23
EVAP canister cover 9