Fuel Tank With Attachments, AWD
Fuel Tank with Attachments, AWD
Special tools, testers and auxiliary items required
• Engine/transmission jack (V.A.G 1383 A)
Removing
Observe safety precautions, refer to => [ Safety Precautions ] Service Precautions.
Observe rules for cleanliness, refer to => [ Clean Working Conditions ] Clean Working Conditions.
• For removal, fuel tank must be empty for weight reasons. Empty fuel tank if necessary. Refer to => [ Fuel Tank, Draining, AWD ] Fuel Tank, Draining, AWD.
- Release the fuel tank flap.
Risk of destroying electrical components when battery is disconnected.
• Observe measures when disconnecting battery.
- Disconnect battery.
- Remove rear seat bench.
- Unclip catches - arrows - of right connector flange cover.
- Disconnect electrical harness connector - arrow - at locking flange.
- Unclip the retainers - arrows - of the cover for left sealing flange.
- Disconnect electrical harness connector - 1 - at locking flange.
- Disconnect electrical connector - 2 -.
- Open the fuel tank flap.
- Clean the area around the fuel filler tube.
- Remove fuel filler cap - arrow - from fuel filler tube.
- Close off the opening of the fuel filler tube with a clean piece of foam to prevent dirt from falling in.
- Remove right rear wheel housing liner.
- Disconnect vent line - 1 -.
- Separate the electrical connector - 2 -.
- Disconnect vent line - 3 - by pressing release button.
- Remove nuts - arrows -.
- Disengage diagnostic pump with bracket.
- Remove the vent line - 1 - to EVAP canister by pressing release button.
- Unclip vent line from bracket.
- Remove the electrical wiring - 2 - for the ABS speed sensor from the fuel filler tube bracket.
- Remove the bolts - arrows - for fuel filler tube.
- Disconnect the vent line - arrow - to EVAP canister by pressing release button.
- Remove the nuts - 1 - and - 2 - and remove the rear crossmember for the underbody.
Using wire, secure the shield of the decoupling element for the front section of the exhaust system to the underbody, before loosening the threaded connections of the clamping sleeve - 3 -.
- Separate exhaust system at clamping sleeve - 3 -.
- Unhook the rear muffler at the retaining loops - arrow - and remove rear section of exhaust system.
• A second technician is required to remove rear portion of exhaust system.
- Remove heat shield for driveshaft - arrows -.
- Remove the driveshaft.
- Separate vent lines - 1 - (white) and - 3 - (green) from right front of fuel tank, by pressing the release button.
There is a risk of injury because the fuel is under high pressure.
• Before opening the fuel system, lay a clean cloth around the connection point and carefully loosen it, which lowers the pressure.
- Disconnect the fuel line - 2 - (black) at fuel filter by pressing release button.
For weight reasons, fuel tank must be empty for removal.
- First remove bolts - 2, 5 - and - 6 -.
- Where necessary, detach and free up the wiring harness - arrows -.
- Place the (V.A.G 1383 A) under the fuel tank for support.
- Remove bolts - 1, 3, 4 - and - 7 -.
- Lower the fuel tank with the (V.A.G 1383 A), thereby guiding it by hand.
- By turning it accordingly, lower the fuel tank sideways and remove it.
- A second technician is required to guide out the fuel filler tube by hand at the longitudinal member.
Installing
• Tightening specifications, refer to => [ Fuel Tank with Attachments Overview, AWD ] Fuel Tank With Attachments Overview, AWD.
Installation is in reverse order of removal, note the following:
- Check if the ground (GND) wiring on both connections show signs of oxidation, remove if necessary.
- Check the installation position of the ground (GND) connection:
• The connector - 4 - must be securely attached to the metal ring - 3 -.
• Engage the contact - 2 - in the fuel tank - 5 - and secure it with the spacer bushing - 1 -.
- Position the fuel tank with mounting straps to underbody using the (V.A.G 1383 A).
- Attach wiring harness at top of fuel tank.
- Make sure the fuel tank is positioned so that the filler tube can be correctly guided into the opening of the body.
- First tighten fuel tank at points - 1, 3, 4 - and - 7 -, then at - 2, 5 - and - 6 -.
- Secure the fuel filler tube with the collar bolts - arrows -; thereby the rear of the two bolts secures the ground contact at the same time.
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 ohm.
- Install ventilation line - 1 - to EVAP canister.
• Vent line must engage audibly.
- Engage the electric wire - 2 - from the ABS speed sensor on the filler tube bracket.
- Install leak detection pump with bracket. Refer to => [ Leak Detection Pump ] Leak Detection Pump.
- Install right rear wheel housing liner.
- Install driveshaft.
- Install rear section of exhaust system.
- Install rear seat bench.
- Connect battery. Observe safety precautions after connecting battery.