Fuel Tank With Attachments With Reducing Agent Metering System
Fuel Tank with Attachments with Reducing Agent Metering System
Special tools, testers and auxiliary items required
• Engine/Transmission Jack (V.A.G 1383 A)
• Support (T10031)
• Carpet knife, commercially available
Removing
Follow all safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.
Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.
Risk of accident due to fuel tank weight.
• The fuel tank must be empty when removing it.
- Drain the fuel tank. Refer to => [ Fuel Tank with Reducing Agent Metering System, Draining ] Procedures.
- On a vehicle with air suspension, activate vehicle lift mode.
- Switch off ignition and remove ignition key.
Danger due to reducing agent leaking out.
• To prevent large amounts of reducing agent when opening the metering line, wait for the recirculation process to complete. Refer to Description and Operation.
- Remove the left single seat and the left 2/3 seat bench seat cushion in the second row of seats.
- Remove the right single seat in the second row of seats.
Risk of injury.
• Wear protective gloves.
- Cut the floor covering along the perforation - arrows - on the left and right sides with a carpet knife - 1 -.
- Fold carpet cut-out to side - arrow -.
- Remove the left and right nuts on the locking flange cover - 1 to 4 - and then remove the cover.
- Disconnect the electrical connector - arrow - on the left locking flange.
• Place a clean cloth under the separating location to catch any fuel that may leak out.
Very hot fuel can burn skin.
• In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
• Wear protective gloves.
• Wear safety glasses.
There is a risk of injury because the fuel is under pressure.
• To reduce pressure in the fuel system, lay a clean cloth around the connector and carefully loosen connector.
- Disconnect the fuel return line - 1 - and the fuel supply line - 2 - from the right locking flange by pressing the release buttons.
- Disconnect the connector - 3 - on the right locking flange.
- Open the fuel tank flap.
- Clean the area around the fuel filler tube.
- Remove the locking cap - 1 - from the fuel filler tube.
- Remove the locking cap - 2 - from the reducing agent filler tube.
• Seal the openings on the filler tube with clean plugs to prevent dirt from possibly getting into the chambers.
- Remove the tank door unit and the rubber buffer.
- Remove the fuel filler tube bolts - arrows -.
Risk of vehicle tipping on hoist with rear axle removed.
• Secure the vehicle on a hoist before loosening the subframe bolts (for example, load the luggage compartment with about 50 kg).
- Remove rear axle.
- Hang driveshaft - 1 - on body with a suitable chain or with welding wire as shown in illustration - arrows -.
• Driveshaft CV joints must only be moved without force and only as far as stop which is approximately a 10° angle.
- Lower driveshaft by dimension - a -.
• Dimension - a - = 220 mm (8.66 in.).
- Remove the right rear wheel housing liner.
- Remover the reducing agent active tank.
- Disconnect the Ground (GND) wire - 1 - from the fuel filler tube.
- Remove the fuel filler tube bolts - arrows -.
- Remove the nuts - arrows - and then remove the fuel filler tube protective plate - 3 -.
- Drive pins - 1 - through with a punch.
- Remove the bracket - 2 - with the lines from the longitudinal member.
- Remove the left and right bolts on the floor panel trim near the fuel tank.
- Remove the reducing agent passive tank.
• Place a clean cloth under the separating location to catch any reducing agent that may leak out.
The reducing agent can cause skin irritation.
• Avoid contact with skin and eyes! Always wear protective gloves and safety glasses.
• If reducing agent should get on your skin, wash it off immediately with soap and water.
• If reducing agent gets in your eye, rinse the eye for several minutes with water.
• Never inhale or swallow the reducing agent!
• Should you swallow any reducing agent, rinse your mouth, drink plenty of water and contact a doctor immediately.
- Remove the metering line - 2 - by pressing the release button.
- Disconnect the connector - 1 -.
- Unclip the fuel supply line - 1 - and the fuel return line - 2 - on the fuel tank - arrows -.
- Unclip parking brake cable bracket - 3 - at fuel tank.
- Place the (V.A.G 1383 A) with (T10031) (without threaded rods) under fuel tank for support, as shown in illustration.
• The (T10031) mounting plates must be positioned near the round impressions in the bottom of the fuel tank.
- Support fuel tank with the (V.A.G 1383 A) and (T10031).
- A 2nd technician must also support the fuel tank by hand.
- Identify location of the fuel tank securing bands.
Risk of accident due to fuel tank weight.
• The fuel tank must be empty when removing it.
- Remove bolts - 1 to 10 - and remove securing bands and carrier plate.
• To improve clarity, the fuel tank is shown without the (V.A.G 1383 A).
- Next lower back of fuel tank to driveshaft.
- A second technician must also support the fuel tank by hand at the rear edge.
- Carefully guide filler tube out of the wheel housing so avoid paint damage.
- Lower fuel tank with the (V.A.G 1383 A) while a 2nd technician guides it.
Installing
• For the correct tightening specifications, refer to => [ Fuel Tank with Attachments with Reducing Agent Metering System Overview ] Fuel Tank With Attachments With Reducing Agent Metering System Overview.
- Make sure the lines are clipped to the fuel tank.
- Position fuel tank on the vehicle underbody using the tensioning bands and carrier plate with the (V.A.G 1383 A) and (T10031).
- Make sure the fuel tank is positioned so that the filler tube can be correctly guided into the opening of the body.
- Tighten the bolts in the sequence described to secure the fuel tank to the vehicle underbody.
- Support plate - 7, 8, 9 and 10 -.
- Rear left and right tensioning band - 1, 4, 5 and 6 -.
- Front right tension strap - 2 and 3 -.
- Tighten the fuel filler tube bolt - 2 -.
- Check if the Ground (GND) wiring - 1 - and the contact show signs of oxidation. If necessary, remove.
Danger due to electrostatic charge.
• After installing, check electrical connection on fuel filler neck metal ring to an empty spot on the body using an Ohm meter.
• Specified value: Approximately 0 ohms.
- Tighten the fuel filler tube - arrows -.
Install in reverse order of removal paying attention to the following:
- Install the rubber buffer and the fuel door unit.
- Install rear axle.
- Tighten the left and right floor panel trim in the center.
- Install rear right wheel housing liner.
- On a vehicle with air suspension, deactivate vehicle lift mode.
- Install the locking flange covers. Refer to => [ Locking Flange Cover - Tightening Specifications ] Fuel Tank With Attachments With Reducing Agent Metering System Overview.
- Install the left single seat and the left 2/3 seat bench seat cushion in the second row of seats.
- Install the right single seat in the second row of seats.