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

CAUTION:
- For removal, fuel tank must be empty for weight reasons. Drain fuel tank if necessary. Procedure Fuel tank, draining.
- 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 cap briefly and then close again.

Sedan:
- Remove carpeting in luggage compartment.
- Fold forward the right rear seat backrest, if necessary.

Wagon:
- Remove left 1/3 backrest Body Interior - .
- Remove left side luggage compartment trim and dirt tray Body Interior -.







All models:
- Unbolt cover for locking flange in luggage compartment - arrows -.







- Disconnect electrical harness connector -1- at locking flange.
- Disconnect electrical connector -2-.







- Separate ventilation line -1-. Do this by pressing the releasing ring -2- approx. 2 mm in direction - arrow A - and simultaneously pulling ventilation line - arrow B - off.







- Open tank flap and clean the area around fuel filler tube.

NOTE: Do not remove fuel cap.

- Pry tensioning ring - arrow - out from rubber cup and press rubber cup through toward the inside.







- Remove right rear wheel.
- Remove right rear wheel housing liner.
- Remove ventilation line -2- 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 -.







- Remove ventilation lines -1- and -2-. Do this by pressing the releasing ring -3- in direction - arrow A - and simultaneously pulling off ventilation line - arrow B -.
- 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 Suspension, Wheels, Steering.







- 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.







- Disconnect ventilation line -2- and fuel line -1- from right front 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 through 7-.
- Lower fuel tank using engine/transmission jack V.A.G 1383 A.







Instaling
Installation is in reverse order of removal. Note the following:
- Make sure the 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.
- Fasten fuel tank to fastening points -2-, -5-, -3-, -4- first, and then to -1-, -6- and -7-.
- Fasten fuel filler tube.

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

Specification: approx. 0 Ohm.

- Install rear axle Suspension, Wheels, Steering.
- Install rear part of exhaust system.
- Install right rear wheel housing liner, thereby fastening bolt for fuel filler tube Body Exterior -.
- Connect battery. Observe safety precautions after connecting battery Electrical Equipment -.

Torque specifications

Component Nm
Tension straps at body 23
Fuel filler tube to body 23
EVAP canister cover 9