Fuel Tank With Attachments, Removing And Installing
Fuel Tank With Attachments, Removing And Installing
Special tools, testers and auxiliary items required
- Engine/transmission jack V.A.G 1383 A
Removing
Observe safety precautions.
Observe rules for cleanliness.
CAUTION:
- For removal, the fuel tank must be empty for weight reasons. Drain fuel tank if necessary.
- Observe procedures for disconnecting battery.
- Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 - .
- With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
- Open fuel filler flap briefly and then close again.
Sedan:
- Remove carpeting in luggage compartment.
- Fold forward right rear seat backrest, if necessary.
Wagon:
- Remove left 1/3 backrest.
- Remove left side luggage compartment trim and dirt tray.
All models:
- Unbolt locking flange cover in luggage compartment - arrows - .
- Disconnect electrical harness connector - arrow - at locking flange.
- Disconnect ventilation line - 1 - . Do this by pressing releasing ring - 2 - approx. 2 mm in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
- Open tank flap and clean area around fuel filler tube.
NOTE: Do not remove fuel cap.
- Pry tensioning ring - arrow - out from rubber gasket and press rubber gasket through toward inside.
- Remove right rear wheel.
- Remove right rear wheel housing liner.
- Pull ventilation line - 2 - off from fuel filler tube by pressing release buttons.
- Remove bolts - 1 - for fuel filler tube.
- Remove EVAP canister cover at bottom of spare wheel well - arrows - .
- Disconnect ventilation lines - 1 - and - 2 - . Do this by pressing releasing ring - 3 - in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off .
- Unclip ventilation lines - A - at top from bracket - arrow - .
- Remove cover for vehicle floor - arrows - .
- Remove covers - 1 - and - 2 - for vehicle floor.
- Remove rear part of exhaust system.
CAUTION: Before removing the subframe bolts, secure the vehicle against falling over (e.g. load the luggage compartment with approx. 50 kg).
- Remove rear axle.
- Disconnect right parking brake cable at front of fuel tank at areas indicated with - arrows - .
CAUTION: The fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.
- Separate ventilation line - 1 - and fuel line - 2 - from right of fuel tank, by pressing release buttons.
- Place engine/transmission jack V.A.G 1383 A under fuel tank for support.
CAUTION: For weight reasons, fuel tank must be empty for removal.
- Remove bolts - 1 to 7 - .
- Lower fuel tank using engine/transmission jack V.A.G 1383 A.
Installing
Installation is in reverse order of removal. Note the following:
- Make sure fuel and ventilation lines are properly clipped to fuel tank - arrows - .
- Check if ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
- Check installation position of ground (GND) connection:
- Connector - 4 - must be securely attached to metal ring - 3 - .
- Contact - 1 - must be attached into fuel tank - 5 - and be secured with spacer bushing - 2 - .
- Position fuel tank with mounting straps to vehicle floor using engine/transmission jack V.A.G 1383 A .
- Make sure fuel tank is positioned so that the filler tube can be correctly guided into opening of the body.
- First tighten fuel tank at securing points - 2, 5, 3, 4 - and then at - 1, 6, 7 - .
- Fasten fuel filler tube.
CAUTION:
After installing, check electrical connection of the metal ring at fuel filler tube to a blank portion of chassis using Ohm meter:
- Specification: approx. 0 Ohm.
- Install rear axle.
- Install rear part of exhaust system.
- Install right rear wheel housing liner, by fastening screws for fuel filler tube.
- Connect battery. Observe safety precautions after connecting battery.
Torque specifications
Tension straps at body 23 Nm
Fuel filler tube to body 23 Nm
EVAP canister cover 9 Nm