Fuel Tank With Attachments

Fuel Tank with Attachments

Special tools, testers and auxiliary items required

• Engine/Transmission Jack (V.A.G 1383 A)

Removing

- Follow all Safety Precautions. Refer to => [ Safety Precautions ] Service Precautions.

- Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

- Move the passenger seat all the way forward if necessary.


Risk of accident due to fuel tank weight.

• The fuel tank must be empty when removing it. Empty fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Procedures.


Risk of destroying electronic components when disconnecting the battery.

• Observe measures for disconnecting battery.

- Disconnect the battery - arrow -.






- Remove the right 1/3 rear seat.






- Remove the bolts - arrows - and remove the locking flange cover - 1 -.

- Disconnect the electrical connector - 1 - on the locking flange.






- Pull the lock - 1 - upward - arrow A - and press - arrow B -, disconnect the connector - 2 -.






- Open the tank door.






- Clean the area around the fuel filler tube.

- Remove the locking cap - arrow - from the fuel filler tube.

• To prevent dirt from entering the fuel tank, seal the opening with a clean foam piece.

- Remove the right rear wheel.






- Remove right rear wheel housing liner..

- Remove fuel filler tube bolts - 1 and 2 -.

• Ignore - 3 to 7 -.

- Remove rear section of the exhaust system.


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 axle.






- Remove the right floor panel in the center.






- Remove the nuts - 1, 3 and 4 - and remove the bracket - 2 -.


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.

- Disconnect the fuel line - 1 - on the right front of the fuel tank by pressing the release button.






- Press the release button and disconnect the EVAP canister vent line - arrow -.






- Place the (V.A.G 1383 A) under the fuel tank for support.






- Support fuel tank using the (V.A.G 1383 A).


Risk of accident due to fuel tank weight.

• The fuel tank must be empty when removing it.

- Remove the bolts - 1 - and remove the exhaust system bracket - 2 -.






- Remove the bolts - 3 to 6 -.

- Lower the fuel tank with the (V.A.G 1383 A) while guiding it by hand.

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:

- Make sure the fuel and vent lines are clipped to the fuel tank properly.

- Check if the Ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.






- Make sure the filler tube threaded connections - 1 and 2 - are free of corrosion so the ground connection to the body is not affected.

- Route the GND connection - 3 - as illustrated.

- Engage the GND connection contact - 7 - into the opening in fuel tank and then install the spacer bushing - 6 -.

- Make sure the GND connector - 4 - fits securely on the fuel filler tube metal ring - 5 -.

- Position the fuel tank with mounting straps on the underbody using the (V.A.G 1383 A).






- Make sure the fuel tank is positioned so that the filler tube can be guided into the opening of the body correctly.

- Install the exhaust system bracket - 2 - and tighten the bolts - 1 through 6 -.

- Tighten the fuel filler tube bolts - 1 and 2 -.







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.

- Install the bracket. Refer to => [ Bracket - Tightening Specification ] Fuel Tank With Attachments Overview.

- Install the rear axle.

- Install the floor panel..

- Install the rear section of the exhaust system.

- Install the rear right wheel housing liner.

- Mount the right rear wheel.

- Install the right locking flange cover. Refer to => [ Locking Flange Cover - Tightening Specifications ] Fuel Tank With Attachments Overview.

- Install the right 1/3 rear seat.

- Connect the battery and observe safety precautions after connecting battery.