Fuel Tank With Attachments

Fuel Tank with Attachments

Special tools, testers and auxiliary items required

• Engine-/Gearbox Jack (V.A.G 1383 A)

Removing

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

- Follow the guidelines for clean working conditions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

Danger of causing damage to other electronic components when disconnecting the battery.

• Complete the steps for disconnecting the battery.

- Disconnect the battery.

Risk of accident due to the weight of the fuel tank.

• The fuel tank must be empty when removing it.

- Drain the fuel tank. Refer to => [ Fuel Tank, Draining ] Procedures.

- Remove the rear bench seat.






- Remove the locking flange cover - arrows -.

- Disconnect the connectors - 1 and 2 - on the locking flange.






- Open the fuel filler 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 -.

- Remove the 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 the rear axle.








There is a risk of injury because the fuel is under high pressure.

• To reduce pressure in the fuel system, lay a clean cloth around the connector and carefully loosen connector.

- Press the release button and disconnect the right front fuel line - 1 - from the fuel tank.

- Disconnect the vent line - 1 - on the left of the Evaporative Emission (EVAP) canister by pressing the release button.






- 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 the weight of the fuel tank.

• The fuel tank must be empty when removing it.

- Remove bolts - 1 through 5 - and remove the accessory assembly bracket - 6 -.

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

Installing

• Tightening specification, refer to => [ Fuel Tank with Attachments Overview ] Fuel Tank With Attachments Overview.

Install in reverse order of removal. Note the following:

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

- Position the fuel tank with the mounting strap and carrier plate on the vehicle 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 - 6 - and tighten the mounting strap and carrier plate bolts - 1 through 5 -.

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






- 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 rear axle.

- Install the rear section of the exhaust system.

- Install the right rear wheel housing liner.

- Mount the rear wheel.

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

- Install the rear bench seat.

- Connect the battery.