Fuel Tank With Attachments, Removing and Installing - Up to 10.04
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 Safety precautions when working on fuel supply system.
Observe rules for cleanliness 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 -.
- Disconnect ventilation line - 1 -. Do this by pressing releasing ring - 2 - approx. 2 mm in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
- Remove rear seat bench
- Unbolt cover for locking flange, left and right - arrows -.
- Disconnect electrical harness connector - 1 - at right locking flange.
- Disconnect electrical connector - 2 -.
- 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 the inside.
- Remove right rear wheel.
- Remove right rear wheel housing liner.
- Remove ventilation line - 2 - from fuel filler tube by pressing release buttons.
- Remove bolt - 1 - for fuel filler tube.
- Remove EVAP canister cover at bottom of spare wheel well - arrows -.
- Disconnect 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.
- Disconnect fuel line - 1 - and right ventilation line - 2 - 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 ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
- Check installation position of ground (GND) connection:
- The connector - 4. must be securely attached
- The 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 the 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 bolt for fuel filler tube
- Connect battery. Observe safety precautions after connecting battery.
Torque specifications
Component Nm
Mounting straps and carrier plate 23
for fuel tank to body
Fuel filler tube to body 23
EVAP canister cover 9