Removal and Replacement

Fuel Tank

CAUTION!
During all repair procedures on the fuel tank, be aware of the following:

• Route all the various lines (for example, fuel, Evaporative Emission (EVAP) or vacuum) and electrical wiring so that the original routing positions are restored.

• Make sure that the ground (-) strap between the fuel filler tube and body is securely fastened, to prevent electrostatic charging.

• Ensure sufficient clearance to all moving or hot components.

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

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

Requirements

• The fuel tank must be drained. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

Removing

- Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.

- Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

- Fold the rear seat bench forward. On vehicles from 12.06, the rear seat bench must be removed.

- Cut open the carpet on the right side from points - A to B - in the pre-cut area - arrow -.





- Remove the fuel delivery unit cover nuts - 1 - on the right side. It may be necessary to remove the backrest support - 2 - or the support mounting.





CAUTION!
The fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then release pressure by carefully disconnecting the connection.

- Disconnect fuel supply line - 1 -, auxiliary heater fuel line - 2 -, fuel pump connector - 3 -, vent line - 4 - and fuel pump control module (J538) connector - 5 -.





• Press in the securing ring to disengage the lines.

- Remove the mufflers and mountings. Refer to => [ Muffler and Mounts Overview ] Description and Operation.

- Remove the rear driveshaft.

- Remove the rear subframe.

- Open the fuel tank flap and remove the fuel tank cap.

- Pull the rubber gasket off the filler neck.

- Remove the bolts - 1 - for the filler neck and disconnect the ground wire - 2 -.





- Remove the right rear wheel housing liner.

- Remove the cover plate bolts - arrow - and plate.





- Unclip the ventilation lines that are secured on the longitudinal member with clips from the fuel tank.





- Remove the bolts for the filler pipe - 1 - and Evaporative Emission (EVAP) canister - 2 - in the wheel housing.





- Bend the filler neck slightly downward and pull off ventilation line connections to the EVAP canister.





• Release the connections by pressing the button on the hose coupling.

- Disconnect the ground wire clipped to the EVAP canister and remove the canister.

- Disconnect the connector to the left fuel pump near the fuel tank.





- Remove the securing straps with covers on the left and right below the fuel tank.

- Support fuel tank using the (V.A.G 1383 A) and remove the securing strap at the center of the fuel tank.

- Carefully lower the fuel tank about 30 cm.

- Grab between fuel tank and vehicle floor and disconnect the vent line from the left sensor flange.

• This step eliminates having to cut open the carpeting in the vehicle interior in the vicinity of the flange cover.

- Lower the fuel tank.

Installing

Installation is performed in the reverse order of removal, noting the following:

• Connections for the ventilation and fuel lines must engage audibly when joined.

• Make sure the ventilation and fuel lines are not kinked when installed.

• The flange seal should be replaced each time it is opened.

• Secure the fuel hoses with spring type clamps.

• Ensure the fuel hoses are securely seated.

• The ground strap at the fuel filler tube - 2 - must be securely connected to the body.





• Before fastening the fuel tank, check that the supply and ventilation lines are still clipped onto the fuel tank.