Fuel Tank with Attachments

Fuel Tank with Attachments

Special tools, testers and auxiliary items required

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

• Support (T10031)

• Release Tool (T40225)

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 Ground (GND) cable - 2 - from 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.

- Open the fuel filler door.






- Clean the area around the fuel filler tube.

- Remove the fuel filler cap - arrow -.

• Seal the fuel filler tube opening with a clean plug to prevent dirt from getting into the tube.

- Remove the fuel filler door insert.






- Disconnect the GND wires - 1 and 2 - from he shield and metal ring on the fuel filler tube.

- Remove the bolts - 3 - from the fuel filler tube.

- Remove the right rear wheel.

- Remove right rear wheel housing liner..

- Press the release button - 2 - and disconnect the breather line - 1 - from the EVAP canister.






- Remove the nuts - 1 -.






- Remove the chafe protection - 3 -.

- Place the (T40225) on the release ring - 4 -, push it in - arrow - and pull the breather line - 2 - off the connection.

- Remove the rear section of the exhaust system.

Risk of vehicle tipping on hoist with rear axle removed.

• Secure the vehicle to the vehicle hoist before loosening the subframe bolts.

- Remove the subframe and its attachments.

- Disconnect the connectors - 1 and 2 - on the right side of the fuel tank.






- Disconnect the connector - 3 - on the metering pump, if equipped.

- Disconnect the connectors - 1, 2 and 3 - on the right side of the fuel tank.






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 - 2 - from the fuel tank.






- Place the (V.A.G 1383 A) with the (T10031) (without the threaded rods) and support the fuel tank, as illustrated.






- A second technician must also support the fuel tank by hand at the rear edge.








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

• The fuel tank must be empty when removing it.

- Remove the bolts - 1 to 7 -.

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

• To improve clarity, the fuel tank is shown without the engine/transmission jack.

Installing

Install in reverse order of removal. Note the following:

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

- Make sure the fuel/breather line, the fuel pump wiring harness and the fuel level sensors are clipped to the fuel tank.

- Make sure the connectors are connected securely to the locking flanges.

- Position the fuel tank with mounting straps and plate to vehicle floor using the (V.A.G 1383 A) and (T10031).






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

- Tighten the bolts - 1 through 7 -.

- Tighten the bolts - 3 - on the fuel filler tube.






- Check the GND wires - 1 and 2 - for traces of oxidation on the connectors. Remove any oxidation if necessary.

- Connect the GND wires to the shield and metal ring on the fuel filler tube. Make sure the connectors are secure.

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 subframe and its attachments.

- Install the rear section of the exhaust system.

- Install the rear wheel housing liner..

- Install the rear wheel.

- Install the fuel filler door insert.

- Connect the battery. Be sure to read the procedures after connecting the battery.