Fuel Tank With Attachments

Fuel Tank with Attachments

Special tools, testers and auxiliary items required

• Engine/Transmission Jack (V.A.G 1383 A)

• Support (T10031)

Removing

Follow all safety precautions. Refer to => [ Safety Precautions ] General Information.

Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

- On a vehicle with air suspension, activate vehicle lift mode.

- Open the fuel filler door.

Risk of destroying electronic components when disconnecting the battery.

• Observe measures for disconnecting battery.

- Disconnect the battery.

Risk of injury due to fuel tank weight.

• Fuel tank must be empty to remove.

- Empty fuel tank. Refer to => [ Fuel Tank, Draining ] Procedures.

Risk of vehicle tipping on hoist with rear axle removed.

• Before removing the subframe bolts, secure the vehicle (for example load the luggage compartment with approximately 50 kg).

- Remove rear axle.

- Hang driveshaft - 1 - on the 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.

- Clean the area around the fuel filler tube.

- Remove fuel filler cap - arrow - from fuel filler tube.






- Close off the opening of the fuel filler tube with a clean piece of foam to prevent dirt from falling in.

- Remove the fuel filler door insert.






- Pry out rubber gasket - 1 - and remove it outward.

- Remove the bolts - arrows - for fuel filler tube.






- Remove the right rear wheel housing liner.






- Disconnect the vent lines - 1 and 2 -.

- Remove the vacuum line - 3 - from the Leak Detection Pump (LDP) (V144).

- Disconnect Ground (GND) wire - 4 - from fuel filler tube.

- Remove the bolts - 5 and 6 - from the fuel filler tube.

- Remove fuel filler tube protective plate - arrows -.






- Drive pins - 1 - through with a punch.

- Remove bracket - 2 - with vent lines from the longitudinal member.

- Remove the sill panel cover bolts marked with an - arrow - on the left side of the underbody.






- Remove the sill panel cover bolts marked with an - arrow - on the right side of the underbody.






- Unclip lines - 1 to 3 - at fuel tank and bracket - arrows -.






- Unclip parking brake cable bracket - 4 - at the fuel tank.

- Disconnect fuel pump and fuel level sensor electrical connectors - 1 and 2 - at left longmember.






- Place the (V.A.G 1383 A) with (T10031) (without threaded rods) under fuel tank for support, as shown in the illustration.






• The (T10031) mounting plates must be positioned near the round impressions in the bottom of the fuel tank.

- Support fuel tank with (V.A.G 1383 A) and (T10031).

- A 2nd technician must also support the fuel tank by hand.

- Identify location of fuel tank securing bands.






Risk of injury due to fuel tank weight.

• The fuel tank must be empty when removing it.

- Remove bolts - 1 through 12 - 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 to avoid paint damage.

- Thread through gap between body and fuel tank.






Risk of injury from fuel.

• To reduce residual pressure remaining in the fuel system, lay a clean cloth around the connector and carefully loosen connector.

- Disconnect fuel line - 3 - by pressing release buttons.

- Disconnect ventilation line - 1 - and vacuum line - 2 - by pressing the release buttons.

- Lower fuel tank using (V.A.G 1383 A) while a 2nd technician guides it.

Installing






• Tightening specifications, refer to => [ Fuel Tank with Attachments Overview ] Fuel Tank With Attachments Overview, => [ Fuel Tank, Tightening Specifications and Sequence ] Fuel Tank With Attachments Overview.

- Check whether vent line and wiring harness to fuel pumps and fuel level sensors are clipped in at fuel tank.

- Position the fuel tank with mounting straps and plate to vehicle floor using 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 this sequence: plate, left and right rear tensioning straps and left and right front tensioning straps. Refer to => [ Fuel Tank, Tightening Specifications and Sequence ] Fuel Tank With Attachments Overview.

- Tighten the bolts - 5 and 6 - for the fuel filler tube.






- Check if the Ground (GND) wiring - 4 - and the contact show signs of oxidation. If necessary, remove.

Risk of explosion due to electrostatic charge.

• After installing, check electrical connection on the fuel filler neck metal ring to an empty spot on the body using an Ohm meter.

• Specified value: Approximately 0 ohms.

- Connect vacuum line - 3 - to fuel system diagnostic pump.

- Install the vent lines - 1 and 2 -.

- Tighten fuel filler tube in place - arrows -.






Install in reverse order of removal paying attention to the following:

- Install the fuel filler door insert.

- Install rear axle.

- Install right rear wheel housing liner.

- Be sure to follow the procedure for connecting the battery and afterwards.

- On a vehicle with air suspension, deactivate vehicle lift mode.