Fuel Tank With Attachments
Fuel Tank with Attachments
Special tools, testers and auxiliary items required
• Engine/Transmission Jack (V.A.G 1383 A)
• Hooks (3004)
Removing
Follow all safety precautions. Refer to => [ Safety Precautions ] General Information.
Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Open the fuel filler door.
Risk of destroying electronic components when disconnecting the battery.
• Observe measures for disconnecting battery.
- Disconnect the battery.
Risk of accident due to weight of fuel tank.
• The fuel tank must be empty when removing it.
- Drain the fuel tank. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
- 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 the right rear wheel housing liner.
- Remove the bolts - 3 and 4 - from the fuel filler tube.
- Remove the ventilation line - 2 - from the EVAP canister.
- Remove the electrical wiring - 1 - for the ABS speed sensor from the fuel filler tube bracket.
- Free up overflow hose - 5 - on fuel filler tube.
- Remove diagonal braces.
- Disconnect the vent line - arrow - to EVAP canister by pressing release button.
The decoupling elements in the front exhaust pipe could get damaged.
• Flex joints in front exhaust pipe must not be bent more than 10°.
• Secure front section of the exhaust system on the underbody with a chain before loosening clamping sleeve bolts.
- Separate exhaust system at clamping sleeve - 1 -.
- Tie up the front section of the exhaust system with a chain. To do this, engage (3004) in openings on underbody (remove plugs if necessary).
- Push the clamping sleeve rearward to separate the exhaust system.
• A second technician is needed to help remove the rear section of the exhaust system.
- Unhook the rear muffler from the retaining loops and remove rear portion of exhaust system.
- Remove the driveshaft.
- Disconnect the right front vent line - 2 - on the fuel tank by pressing release button.
There is a risk of injury because the fuel is under high pressure.
• To reduce the pressure in the fuel system, lay a clean cloth around the connector and carefully loosen connector.
- Disconnect right front fuel line from the fuel tank.
Risk of accident due to fuel tank weight.
• The fuel tank must be empty when removing it.
- First remove bolts - 2, 5 and 6 -.
- 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 -.
Danger of twisting the electric wires too much.
• Do not pull on the electric wires when lowering the fuel tank.
- Lower the fuel tank with the (V.A.G 1383 A) until the connectors on the locking flanges are accessible.
• Both illustrations show the connectors installed on the locking flanges.
- Disconnect electrical harness connector - 1 - at left locking flange.
- Disengage the connector - 2 - from the Haldex clutch.
- Disconnect electrical harness connector - arrow - at right locking flange.
- 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
• For the correct tightening specifications, refer to => [ Fuel Tank with Attachments Overview ] Fuel Tank with Attachments Overview.
Install in reverse order, paying attention to the following:
- Position the fuel tank with mounting straps to underbody using the (V.A.G 1383 A).
- Attach wiring harness at top of the 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 securing points - 1, 3, 4 and 7 - and then at - 2, 5 and 6 -.
- Ensure filler tube threaded connections - 2 and 4 - are free of corrosion so the Ground (GND) connection to the body is not affected.
- Tighten fuel filler tube bolts - 4 - and - 5 -.
- Check if the GND wiring on both connections show signs of oxidation, remove if necessary.
- Route GND connection - 1 - as shown in illustration.
- Ensure GND connection connector - arrows - is seated firmly on protective plate - 5 - and on filler tube - 3 -.
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: Approximately 0 ohms.
- Attach the electrical wiring for the ABS speed sensor to the fuel filler tube bracket.
- Install ventilation line to EVAP canister on filler tube.
- Install rear right wheel housing liner.
- Install the driveshaft.
- Install the rear section of the exhaust system.
TT Roadster:
- Install diagonal braces.
All Vehicles:
- Connect the battery. Observe safety precautions after connecting battery.