Fuel Tank, Removing and Installing

Fuel Tank With Attachments, Removing and Installing (Front wheel drive)


- Observe safety precautions.
- Observe rules for cleanliness.

Special tools and equipment







- VAG1383A with VAG1359/2

Removing
- Note radio code (for vehicles equipped with coded anti-theft radio). Obtain if necessary.







- If installed, remove cover above battery.
- Open battery protective casing (Velcro).







- Switch ignition off and disconnect battery Ground (GND) strap (arrow).
- Remove fuel from tank if necessary. Refer to "Fuel Tank Emptying (Front wheel drive)", Testing and Inspection


NOTE: For weight reasons, fuel tank must be emptied for removal.


- Remove rear seat bench -2-.
- Unscrew cover at right beneath rear seat bench.







- Disengage 4 - pin electrical harness connector (arrow) and remove carefully.
- Open fuel flap.
- Clean area surrounding fuel filler unit.
- Remove fuel filler cap from fuel filler unit.
- Remove rear axle.
- Remove center and rear muffler of exhaust system.







- Remove mounts -1- and -2- for rear muffler.
- Remove heat shield for rear muffler (arrows).
- Remove right-rear wheel housing liner.







- Unscrew Ground (GND) wire -2- and screws -1- for fuel filler unit.


WARNING!
Fuel supply pipes are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.







- Disconnect return line -1- (blue), supply line -2- (black) and vent line -3- (white) front right at fuel tank (press release button).


NOTE: Electric wire to Leak Detection Pump (LDP) -V144- will not be disconnected.







- Disconnect vent lines -1- and -2- to EVAP canister.
- Place VAG1383A engine/transmission lifter under fuel tank to retrieval.







- Loosen screws (arrows). Begin at retainer strap (lower left arrow).
- Lower fuel tank.

Installing
Installation is the reverse of removal, noting the following:







- Engage Ground (GND) connection at both retaining clips (arrows).

NOTE:
- The illustration depicts Ground (GND) wire routing when fuel tank is removed.
- Depending on construction version, a cable binder may be implemented in place of a clip.


- Position fuel tank and mounting straps at vehicle floor using VAG1383A engine/transmission lifter.







- Secure fuel tank at mounting points (arrow) using bolts (26 Nm).
- Bolt mounting straps first.







- Tighten bolts -1- (11 Nm) and screw on Ground (GND) connection -2- (10 Nm).


WARNING!
- Be absolutely sure the Ground connection is secured and that the connector at the fuel pump unit is securely fastened See page 20-11, Fig.1.
- After installing, check electrical Ground connection using ohmmeter
- Specified value: 0 Ohms


- Check installation position of rubber cup. Refer to "Tank Flap, Component Overview (Front wheel drive)", Locations
- After connecting battery, enter anti-theft radio code.
See Radio operating instructions
- Using power window switch, raise windows to stop.
- Operate all power window switches ("up") for at least one second to activate automatic window raising/lowering.
- Set clock to correct time.
- Install rear right wheelhousing.
- Install and adjust (tension free) center and rear muffler of exhaust system.
- Install rear axle.
- Generate readiness code.

Tightening torques

Component Nm

Mounting straps for fuel tank to chassis 26
Fuel tank to chassis 26
Fuel filler unit to bracket 11
Ground (GND) line at wheel housing 10
Battery terminal to battery post 5