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 => [ Safety Precautions ] Service Precautions.
Observe rules for cleanliness, refer to => [ Clean Working Conditions ] Clean Working Conditions.
• For removal, fuel tank must be empty for weight reasons. Empty fuel tank if necessary, refer to => [ Fuel Tank, Draining, FWD ] Fuel Tank, Draining, FWD.
- Release the fuel tank flap.
Risk of destroying electrical components when battery is disconnected.
• Observe measures when disconnecting battery.
- Disconnect battery.
- 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 right rear wheel housing liner.
- Disconnect vent line - 1 -.
- Separate the electrical connector - 2 -.
- Disconnect vent line - 3 - by pressing release button.
- Remove nuts - arrows -.
- Remove leak detection pump with bracket.
- Remove the vent line - 1 - to EVAP canister by pressing release button.
- Unclip vent line from bracket.
- Remove the electrical wiring - 2 - for the ABS speed sensor from the fuel filler tube bracket.
- Remove the bolts - arrows - for fuel filler tube.
- Disconnect the vent line - arrow - to EVAP canister by pressing release button.
Audi A3 Cabriolet:
- Remove the stone deflector - 3 - on the right of the longitudinal member 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.
- Separate vent lines - 1 - (white) and - 3 - (green) from right front of fuel tank, by pressing the release button.
There is a risk of injury because the fuel is under high pressure.
• Before opening the fuel system, lay a clean cloth around the connection point and carefully loosen it, which lowers the pressure.
- Disconnect the fuel line - 2 - (black) at fuel filter by pressing release button.
- First remove the bolts - 1 - and - 3 -.
For weight reasons, fuel tank must be empty for removal.
- 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, Overview, FWD ] Fuel Tank With Attachments, Overview, FWD.
Installation is in reverse order of removal, note the following:
- Check if the ground (GND) wiring on both connections show signs of oxidation, remove if necessary.
- Check the installation position of the ground (GND) connection:
• The connector - 4 - must be securely attached to the metal ring - 3 -.
• Engage the contact - 2 - in the fuel tank - 5 - and secure it with the spacer bushing - 1 -.
- 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 -.
- Secure the fuel filler tube with the collar bolts - arrows -; thereby the rear of the two bolts secures the ground contact at the same time.
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.
- Engage the electric wire - 2 - from the ABS speed sensor on the filler tube bracket.
- Install ventilation line - 1 - to EVAP canister.
• Vent line must engage audibly.
- Install leak detection pump (LDP) with bracket. Refer to => [ Leak Detection Pump ] Leak Detection Pump.
- Install rear section of exhaust system.
- Install diagonal braces.
- Install right rear wheel housing liner.
- Install rear seat bench.
- Connect battery. Observe safety precautions after connecting battery.