Vehicle With Front Wheel Drive

Fuel Tank With Attachments, Removing And Installing

Special tools and equipment







- VAG 1383 A and VAG 1359/2
- The fuel tank must be empty when it is removed from the vehicle in order to reduce weight. Drain fuel tank if necessary.


WARNING: Observe safety precautions when disconnecting the battery.


- With ignition switched off disconnect battery ground strap.
- Open fuel filler cap briefly, then close it again.

Sedan:
- Detach trim in luggage compartment.
- Fold down rear right seat backrest if necessary.

Avant:
- Remove 1/3 backrest, left.
- Remove left side trim of luggage compartment and protective pan.

All models:







- Detach cover for flange -arrows-.







- Release and remove electrical harness connector -1-.
- Disconnect electrical harness connector -2-.







- Remove ventilation line -1-. For this, press release ring -2- approx. 2 mm in direction of arrow -A- and disconnect ventilation line -arrow B-.
- Remove right rear wheel.
- Remove right rear wheel housing liner.







- Clean area around tank filler neck.
- Open fuel filler flap, pry out tensioning ring (arrow) in rubber top (around filler neck).


NOTE: Do not remove filler cap.


- Press rubber cup through to the inside.
- Remove rear section of exhaust system.


CAUTION: Secure vehicle against tipping over before LOOSENING the subframe bolts (e.g. Load trunk compartment with approx. 50 kg).


- Remove rear axle.







- Remove floor panel covers -1- and -2-.


WARNING: The fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.







- Disconnect fuel supply hose -1- from fuel filter (press release button) and catch escaping fuel.
- Disconnect ventilation line -2- (press release button).







- Disconnect ventilation line -2- from fuel filler neck (press release tabs).
- Unscrew bolt -1- from tank filler neck.







- Unscrew EVAP canister cover at bottom of spare tire well (arrows).







- Remove ventilation lines -1- and -2-. To remove, press release ring -3- in direction of arrow -A- and pull off ventilation line -B-.
- Unclip ventilation lines at top from bracket (arrow).







- Position engine/transmission hoist VAG 1383 A below vehicle to support tank.


WARNING: The fuel tank must be empty when it is removed from the vehicle in order to reduce weight.


- Take out bolts -1 through 7-.
- Lower fuel tank with VAG 1383 A.

Installing
Install in reverse sequence; note the following points:


NOTE: Secure all hose connections with the correct hose clamps (same as original equipment)







- Check that supply pipe, return pipe, breather pipe and vent pipe are clipped onto fuel tank -arrows-.
- Check the ground wiring at both ends for traces of oxidation. Remove any traces of oxidation if necessary.







- Check position of ground connection:
- Make sure connector -4- is connected securely on metal ring -3-.
- The contact tab -1- must be hooked onto the fuel tank -5- and secured via spacer sleeve -2-.

- Position fuel tank on underside of vehicle using engine/transmission jack VAG 1383 A.







- Secure fuel tank by first tightening bolts at points -2- and -5-, then at the remaining points (23 Nm).


CAUTION:
After installation, use an ohmmeter to check the electrical connection between the metal ring on the fuel filler neck and a bare metal part on the body.
- Specification: approx. 0 Ohm.


- Install rear axle.
- Install rear section of exhaust system.
- Install rear right wheel housing liner and tighten fastening bolt for fuel filler neck.
- Observe safety precautions after connecting the battery.

Tightening torques

Component Nm
Securing straps to body 23
Fuel filler neck to body 23
Cover for EVAP canister 9
Battery terminal to terminal post 6