Fuel Tank, Removing and Installing

Fuel Tank, Removing and Installing

Special tools, testers and auxiliary items required

• Torque wrench (5 to 50 Nm) (V.A.G 1331)





• Engine/transmission jack (V.A.G 1383 A)





Removing fuel tank => [ Fuel Tank, Removing ]

Installing fuel tank => [ Fuel Tank, Installing ]

Fuel Tank, Removing

• Rear axle must be lowered to remove fuel tank.

• Read safety precautions before beginning work => [ Safety Precautions ] Table of Contents.

• Observe the rules for cleanliness => [ Clean Working Conditions ] Fuel Supply System.

• Fuel tank, assembly overview => [ Fuel Tank Assembly Overview, Engine Codes BZB, CAWA, CAWB and CGYA ].

- Empty the fuel tank if necessary using the fuel extracting device (VAS 5190) => [ Fuel Tank, Draining ] Procedures.

- Remove rear seat bench => Body Interior 72 Seats, rear.

- Remove cover - 1 - with Fuel Pump (FP) Control Module (J538) - 2 - from fuel delivery unit.





- Disconnect the 5-pin connector - arrow - from the flange.





• On vehicles with auxiliary heater, harness connector of Metering Pump (V54) must also be disconnected.

- Remove right rear wheel.

- Remove right rear wheel housing liner => Body - Exterior
66 Wheel housing liner.

Engine codes BZB, CAWA, CAWB and CGYA:





- Disconnect vent line and pressure retaining valve - arrows - from EVAP canister.

• Grasp pressure retaining valve on circlip (gray) and pull off upward.

Engine codes CBFA, CCTA and CCTB:





- Disconnect vent lines and vacuum line - arrows - from EVAP canister.

All:

- Unclip electrical wire on fuel filler tube.





- Remove tank flap unit screw and remove unit => Body

Exterior 55 Tank flap unit; Tank flap unit, removing and installing.

- Unscrew fuel filler tube from body - arrows -.





CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

- Disconnect ventilation line (white) - 1 - and fuel line (black) - 2 - from connection point.





• Press in securing ring to disengage the fuel line.

• On vehicles with auxiliary heater, fuel line of Metering Pump (V54) must also be disconnected.

- Unclip brake lines - arrow - at left of body.





- Support rear axle using Engine/Transmission Jack (V.A.G 1383 A).

- Loosen mounting bolts - arrows - and lower rear axle.





- Remove the tensioning strap bolts - arrows -. Support fuel tank using Engine/Transmission Jack (V.A.G 1383 A) beforehand.





- Slowly lower fuel tank.

• Fuel filler tube must be "removed" between chassis and rear axle. To do so, lift fuel tank with a second mechanic down from Engine/Transmission Jack (V.A.G 1383 A).

Fuel Tank, Installing

- With a second mechanic assisting, guide fuel filler tube between rear axle and chassis. Then place fuel tank on to engine and transmission jack (V.A.G 1383 A).

- Lift fuel tank slowly up to installation position and secure it.





• To mount the fuel tank tension straps, only screws with loose washers may be used. If other bolts are used, the tensioning straps could twist when the bolts are tightened.

- Secure rear axle to chassis again.

Further installation is performed in reverse order. When doing this note the following:

• Make sure vent and fuel lines are not kinked.

• Make sure lines connections are securely fastened.

• Check Ground (GND) connection of fuel tank/chassis at filler tube.

Tightening specifications:





1) replace