Fuel Tank With Attachments

Fuel Tank with Attachments

Special tools, testers and auxiliary items required

• Engine-/Gearbox Jack (V.A.G 1383 A)

Removing






- Follow all safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.

- Follow the guidelines for clean working conditions. Refer to => [ Clean Working Conditions ] Fuel Supply System.

Danger of causing damage to other electronic components when disconnecting the battery.

• Complete the steps for disconnecting the battery.

- Disconnect the Ground (GND) cable - 2 - from the battery.

Risk of accident due to the weight of the fuel tank.

• The fuel tank must be empty when removing it.

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

- Remove the rear bench seat.






- Fold the insulation mat near the locking flange cover to the side.

- Remove the bolts - arrows - and the locking flange cover.

- Disconnect the connectors - 1 and 2 - on the locking flange.






- Open the fuel filler door.






- Clean the area around the fuel filler tube.

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

• Seal the fuel filler tube opening with a clean plug to prevent dirt from getting into the tube.

- Remove the right rear wheel.






- Remove right rear wheel housing liner.

- Remove fuel filler tube bolts - 1 and 2 -.

- Remove the rear section of the exhaust system.

Risk of vehicle tipping on hoist with rear axle removed.

• Secure the vehicle to the vehicle hoist before loosening the subframe bolts.

- Remove the subframe and its attachments.

- Remove the heat shield from the heat shield.

- Press the release button and disconnect the vent line - 1 - on the Evaporative Emission (EVAP) canister.













There is a risk of injury because the fuel is under high pressure.

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

- Remove the fuel line - 2 - on the front of the fuel tank on the right side.

- Press the connecting piece - 1 - all the way - arrow A - and hold it pressed.






- Press the release buttons - 2 - - arrows B - and remove the connecting piece.

- Place the (V.A.G 1383 A) under the fuel tank to support it as illustrated.






- A second technician must also support the fuel tank by hand at the rear edge.

- Remove the bleed line from the bracket - arrow -.






Risk of accident due to the weight of the fuel tank.

• The fuel tank must be empty when removing it.

- Remove the bolts - 1 to 5 -.

- Lower the fuel tank with the (V.A.G 1383 A) while guiding it by hand.

• To improve clarity, the fuel tank is shown without the (V.A.G 1383 A).

Installing

Install in reverse order of removal. Note the following:

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

- Check the ground wires for traces of oxidation on the connectors. Remove any oxidation if necessary.

- Make sure the following connectors are secure:

• Ground connector - 2 - on the threaded ring - 1 - on the fuel filler tube.






• Ground connector - 6 - on the fuel filler tube cover.

- Attach the ground connection contact - 4 - to the hole in the fuel tank - 3 - and then install the spacer - 5 -.

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.

- Make sure the fuel and vent line is attached to the fuel tank properly.

- Position the fuel tank with the mounting strap and carrier plate on the vehicle underbody using the (V.A.G 1383 A).






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

- Tighten the bolts - 1 through 5 -.

- Attach the bleed line from the bracket - arrow -.

- Install the subframe and its attachments.

- Install the rear section of the exhaust system.

- Install the rear wheel housing liner.

- Install the rear wheel.

- Install the right locking flange cover. Refer to => [ Locking Flange Cover - Tightening Specifications ] Fuel Delivery Unit and Fuel Level Sensor Overview.

- Install the rear bench seat.

- Connect the battery. Be sure to read the procedures after connecting the battery.