Fuel Tank, Removing and Installing

Fuel Tank, Removing and Installing

Special tools, testers and auxiliary items required

• Torque wrench (V.A.G 1331)






Perform the following:

Removing

• Fuel tank may be a maximum of 1/4 full.

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

• Follow all Safety Precautions. Refer to => [ Fuel Supply System, Safety Precautions ] Fuel Supply System, Safety Precautions.

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

- Turn off the ignition and all electric consumers and remove the key.

- Open the fuel filler door and the fuel cap.

- Remove the bench seat. Refer to; Seat Bench, Removing and Installing.

- Remove the cover - 1 - from the fuel delivery unit. Arrow - 2 - points in direction of travel.






- Disconnect the connector - arrow - from the fuel delivery unit.






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

- Remove the bleed line - 1 - from the filler tube. To do so, press in securing ring.






- Remove the bleed line from the bracket - arrow -.

- Remove the bolts - 1 -.

- Remove the ABS line - A - from the retainers - arrows -.







Fuel system is under pressure!

• Wear protective goggles and protective clothing in order to avoid injury and contact with the skin.

• Before loosening line connections, place cloths around the connection point. Then release pressure by carefully pulling off the line.

- Disconnect bleed line from the EVAP canister on the connection location behind the fuel tank.

- Disconnect the white vent line - 1 - and the black supply line - 2 - at the connecting point. Press in securing ring to disengage the lines.






- Loosen the front clamping sleeve - 1 -.






- Push the rear section of the exhaust system out of the retaining straps - arrows -.

- Remove the bolt - 1 -.






- Remove the bumper cover - 2 - in - direction of arrow - and swivel the exhaust system downward.

The exhaust system is then hanging by the rear axle and the rear tunnel brace.

- Push the exhaust system as far as possible to the left.

- If the middle and rear mufflers are separated, then loosen the rear clamping sleeve - 3 - and remove just the front muffler - 2 -.






- Disconnect vent line - 4 -.

• For the continuing work sequence, a second mechanic is needed to support the fuel tank.

- Remove the bolts - arrows -. Have a second technician hold the fuel tank - 1 - while doing this.


Always make sure there is enough clearance for the filler tube to prevent damaging the fuel tank while removing it.

- Swivel the fuel tank downward and pull it as far as possible away from the rear axle. Pay attention to the parking brake cable while doing this.

- Move the fuel tank to the right and downward and then pull it forward.

- Move the fuel tank downward once it it is removed from the rear axle. While doing this turn the fuel tank to the left.

- Remove the fuel tank downward. While doing this turn the fuel tank slightly to the left. The filler tube can then be guided past the rear axle.

Installing

Installation is performed in the reverse order of removal. When doing this note the following:

• Make sure vent and fuel lines are not kinked.

• Do not confuse the supply line and the return line (the supply line is black and the return line is blue).

• Make sure lines connections are securely fastened.

• Check the ground connection on the filler tube to make sure it is secure.

• After installing fuel tank, check to be sure lines are still clipped in at fuel tank.

- Fuel System, Bleeding. Refer to => [ Fuel System, Bleeding ] Service and Repair.

Tightening specifications: