Fuel Tank with Attachments
Fuel Tank with Attachments
Special tools, testers and auxiliary items required
• Engine/transmission jack (V.A.G 1383 A)
Removing
Observe safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.
Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] [1][2]Fuel Injection System.
CAUTION!
Risk of accident due to fuel tank weight.
• Fuel tank must be empty when removing. Drain fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Procedures.
CAUTION!
Risk of destroying electrical components when battery is disconnected.
• Follow the instructions when disconnecting the battery.
- Switch off ignition.
- Release the fuel tank flap.
- Fold rear seat right backrest forward, if necessary.
Sedan:
- Remove luggage compartment floor trim.
Wagon:
- Remove luggage compartment cargo floor - 1 - and spare wheel cover - 2 -.
All:
- Release the retaining clips - arrows - with a screwdriver - 2 - and remove the cover - 1 -.
- Disconnect Ground (GND) strap at battery ground (GND) terminal - arrow -.
Wagon:
- On vehicles without air suspension, unclip right sealing flange cover retainers - arrow -.
- On vehicles with air suspension, unscrew spreader pins - arrows - and remove cover - 1 -.
All:
- On vehicles with air suspension, remove screws - arrows -.
- Remove pressure tank - 2 - and set aside with line connected - 1 -.
• Do not stretch or kink line.
Sedan:
- Release the retaining tabs - arrows -.
- Fold open the retaining tabs - 1 - and - 3 - toward the rear.
- Fold the cover - 2 - toward the front - arrow -.
All:
- Unbolt cover - arrows -.
- Disconnect ventilation line - 1 -. Do this by pressing the releasing ring - 2 - approximately 2 mm in direction - arrow A - and simultaneously pulling the vent line off - arrow B -.
- Remove rear seat bench.
- Unbolt cover for right locking flange - arrows -.
- Disconnect electrical harness connector - arrow - at locking flange.
- 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.
- Remove rear right wheel housing liner.
- Pull vent lines - 1 - and - 2 - off from fuel filler tube by pressing the release buttons.
- Unfasten the bolts - arrows - for fuel filler tube.
- Remove bolts - arrows - and remove cover for EVAP canister.
- Secure the EVAP canister by hand-tightening the unfastened bolts.
- Disconnect vent line - 1 -. Do this by pressing the releasing ring - 2 - approximately 2 mm in direction - arrow A - and simultaneously pulling the vent line off - arrow B -.
- Unclip vent line from bracket.
- Loosen the clamping sleeves - 1 - and - 2 -.
- Push the clamping sleeves rearward to separate the exhaust system.
- Remove rear cross member - arrows -.
• A second technician is required to remove rear portion of exhaust system.
- Unhook exhaust system from retaining loops and remove rear portion of exhaust system.
- Remove left rear cover - 1 - on bottom of vehicle floor.
- Remove right rear cover - 1 - on bottom of vehicle floor.
Vehicles with all wheel drive:
- Remove the driveshaft.
All:
CAUTION!
Risk of vehicle tipping on hoist with rear axle removed.
• Secure the vehicle on a hoist before loosening the subframe bolts (for example, load the luggage compartment with about 50 kg).
- Remove rear suspension.
CAUTION!
There is a risk of injury because the fuel is under high pressure.
• To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.
- Separate fuel line - 2 - and vent line - 1 - at right front from fuel tank, by pressing the release buttons.
- Place the (V.A.G 1383 A) under the fuel tank for support.
CAUTION!
Risk of accident due to fuel tank weight.
• Fuel tank must be empty when removing.
- Remove screws - 1 to 9 -.
- Lower the fuel tank with the (V.A.G 1383 A), thereby guiding it by hand.
Installing
• Assembly overview, refer to => [ Fuel Tank with Attachments Assembly Overview ] Fuel Tank with Attachments Assembly Overview.
• Tightening specifications, refer to => [ Fastener Tightening Specifications ] Fuel Supply System - Fastener Tightening Specifications.
Installation is performed in the reverse order of removal, noting the following:
- Make sure the fuel and vent lines are properly clipped to the fuel tank.
- Check if the ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
- Check the installation position of the ground (GND) connection:
• The connector - 1 - must be securely attached to the metal ring - 2 -.
• Engage the contact - 3 - in the fuel tank - 4 - and secure it with the spacer bushing - 5 -.
- Position the fuel tank with mounting straps and carrier plate to vehicle floor using the (V.A.G 1383 A).
- Make sure the fuel tank is positioned so that the filler tube can be correctly guided into the opening of the body.
- Fasten mounting straps and carrier plate - 1 to 9 -.
- Fasten the fuel filler tube with ground (GND) connection - arrows -.
CAUTION!
Risk of explosion due to electrostatic charge.
• After installing, check electrical connection on fuel filler neck metal ring to an empty spot on the body using an Ohm meter.
• Specified value: about 0 ohms
- Secure vent lines - 1 - and - 2 - to fuel filler tube.
- Install rear suspension.
Vehicles with all wheel drive:
- Install driveshaft.
All:
- Install rear part of exhaust system.
- Install rear right wheel housing liner.
- Install EVAP canister cover. Refer to => [ EVAP Canister ] Service and Repair.
- Install rear seat bench.
- Install pressure tank.
- Connect battery. Observe safety precautions after connecting battery.