Fuel Tank, Removing and Installing

Fuel Tank Assembly, Removing And Installing

Required special tools, testing equipment and auxiliary equipment

- VAG1359/2 Universal holder
- VAG1383 A Engine / transmission jack

Removing


CAUTION!
Obtain the radio Anti-theft code from the customer before disconnecting the Battery Ground strap.







- Disconnect Battery Ground strap with ignition switched OFF.
- Open fuel tank cover briefly and close again.
- If necessary, drain fuel tank using fuel cart.


NOTE: For handling reasons, fuel tank must be empty before removing.

- Remove connector flange cover under luggage compartment trim.







- Unlatch and disconnect 4-pin harness connector -1-.


NOTE: Return line -2- and supply line -3- stay connected.


- Clean area around fuel filler neck.
- With filler cap removed, pry out clamping ring on rubber seal (around filler neck).
- Push rubber seal toward inside.
- Remove right rear wheel.
- Remove right rear wheel house liner.







- Remove screw -2- for fuel filler neck under wheel house liner.







- If present, remove the aerodynamic trim panel from the rear axle -arrows-


WARNING!
Fuel system is under pressure! Before opening, place clean cloths around the connections to be opened. Carefully loosen the connections to relieve pressure.







- Mark and remove the supply line -1- and return line -2-.
- On bottom of vehicle
- Remove EVAP canister cover on bottom of spare tire well.







- Loosen hose connection -1- on bleed line to fuel filler neck.
- Unclip line out from bracket -arrow-.


NOTE: Bleed line -2- to the EVAP canister purge regulator valve remains connected.


- Place VAG1383A engine / transmission jack under fuel tank for support.
- Mark installation position of clamp bands.







- Remove clamp bands -1- to -4-.
- Lower fuel tank.


NOTE: Arrow points in driving direction.


Installing
Installation is performed in the reverse order of the removal procedure, during installation, note the following:


CAUTION!
Always refer to the latest parts catalog to ensure that you use original equipment fuel hose clamps.


NOTE:
- Replace all adhesive tapes removed during disassembly in the original location during installation.
- Use VAG1921 hose clamp pliers to install spring clamps,
- Always replace sealing rings and gaskets during installation work.


- Position fuel tank using clamp strips with VAG1383 A engine/transmission jack on vehicle floor pan.
- Push fuel tank all the way to the left.







- First tighten screws -1- and -2-, then screws -3- and -4-.
- 25 Nm







- Attach wiring terminal -1- with screw -2- for fuel filler neck.


CAUTION!
Ensure that the Ground connection is unfastened and the connector is securely fitted into the fuel filler neck.







- Connect lines according to marks:
1 - Supply line
2 - Return line
- Connect fuel pump and sender for fuel gauge -G harness connectors.


CAUTION!
After installation, check for continuity between Ground clamp on filler neck and chassis Ground.


- Specification: approximately 0 Ohms.
- With ignition switched OFF, connect Battery Ground strap.
- After connecting Battery, input Radio anti- theft coding
- Run door windows up to stop with window switches.
- Operate all window lifters again for at least 1 second in "closed" position to activate the automatic up/down.
- Set the clock.

Tightening torques

Component Nm
Clamp bands for fuel tank on body 25
Aerodynamic trim (on body) in front of rear axle 10
Cover on spare wheel well 10