Fuel Tank With Attachments

Fuel Tank with Attachments

Special tools, testers and auxiliary items required

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

Removing

Observe safety precautions. Refer to => [ Fuel System ] Fuel System.

Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.

• For removal, fuel tank must be empty for weight reasons. Empty fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Procedures.

- Remove rear seat bench.

- Unclip the retainers - arrows - of the cover for sealing flange.






- Disconnect electrical harness connector - arrow - at locking flange.






- Open the fuel tank flap.

- 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 rear right wheel housing liner.






- Unfasten the bolts - 1 - for fuel filler tube.

- Disengage the electric wire - 2 - from the ABS speed sensor on the filler tube bracket.

Audi A3 Cabriolet:

- Remove the right stone chip protective molding - 3 - on the trailing arm by pressing the spreader pins - 1 - and - 2 - out and disengaging the stone deflector - arrows -.






- Remove bolts - 1 through 4 - and remove pendulum support.






All Vehicles:

- Loosen nuts of double clamp - arrows -.






- Push the clamping sleeve rearward to separate the exhaust system.

- Remove the nuts - 1 - and - 2 - and remove the rear crossmember for the underbody.






• A second technician is required to remove rear portion of exhaust system.

- Unhook exhaust system at retaining loops - arrows -.

- Unhook rear muffler from retaining loops and remove rear portion of exhaust system.


• Fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.

• The temperature of the fuel lines or fuel may reach 100 °C (212 °F) after stopping the engine. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.

• Wear protective gloves.

• Wear safety glasses.

- Press the release buttons - arrows - and disconnect the fuel supply line (black) and the fuel return line (blue) on the right side and at the front of the fuel tank.







For weight reasons, fuel tank must be empty for removal.

- First remove the bolts - 1 - and - 3 -.






- Place the (V.A.G 1383 A) under the fuel tank for support.

- Remove the bolts - 2 - and - 4 -.

- By turning it accordingly, lower the fuel tank sideways and remove it.

Installing

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

Installation is in the reverse order of removal, note the following:

- Check if the ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.

- Check the installation position of the ground (GND) connection:

• The connector - 3 - must be securely attached to the metal ring - 2 -.






• Engage the contact - 4 - in the fuel tank - 1 - and secure it with the spacer bushing - 5 -.

- Position the fuel tank with mounting strap to underbody using the (V.A.G 1383 A).






- Make sure the fuel tank is positioned so that the filler tube can be correctly guided into the opening of the body.

- Fasten the fuel tank to the fastening points - 2 - and - 4 - first, and then to - 1 - and - 3 -.

- Fasten wire contact of ground (GND) connection with collar bolt - arrow - for fuel filler tube.







After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter:

• Specified value: approximately 0 ohm.

- Attach the electrical wiring for the ABS speed sensor to the fuel filler tube bracket.

- Install rear part of exhaust system.

- Install diagonal braces.

- Install rear right wheel housing liner.