Section G - Fuel Tank Removal
(2001-2005 4Motion vehicles)- If not already done:
- Save all customer settings (i.e. radio stations, A/C settings)
- Switch off ignition and all electrical consumers
- Disconnect battery ground terminal
WARNING:
- Fire hazard. Do not smoke or work near heaters or have anything in the area that could ignite fuel or fumes
- Fuel system is under pressure. Before opening system, place a cloth around the connection. Release pressure by carefully loosening the connection
- Always wear eye protection and wear fuel resistant gloves when disconnecting system connections
- Open fuel filler cap to relieve tank pressure
- Use VAS 5190 or equivalent to siphon fuel from tank
- Disconnect 4-pin connector from fuel sending unit -arrow-.
- Move exhaust clamp between downpipe and tailpipe rearward to allow exhaust to move freely, then remove exhaust from center and rear hangers to remove exhaust from the vehicle
- Secure drive shaft using a wire or equivalent otherwise the constant velocity joint can be damaged
NOTE:
Ensure drive shaft is secure to avoid damage to the constant velocity joint which is not covered under this action
- Remove rear wheels
NOTE:
It is essential that the installation position is marked -arrows- before the drive shaft is removed, offset installation will cause excessive imbalance or vibration
- Remove drive shaft from rear final drive
- Pull out securing clip -1- and unhook parking brake cable from brake caliper
NOTE:
Do not damage parking brake boot when removing and installing
- Loosen bolt -A- on both sides
- Unhook parking brake cable -B- from retainer -C-
- Repeat on opposite side
[NEW] TIP:
Mark position of rear sub-frame prior to removing bolts
- Press locking tabs -A- together and push parking brake cable -2- out from control arm -1-
- Remove control arm -1- from shock absorber by removing bolt -3-.
- Repeat on opposite side
- Remove securing bolts -arrows- from brake caliper housing, while holding guide pins
- Remove brake caliper housing and secure with wire so weight of the brake caliper does not stress or damage brake hose
- Unbolt vehicle speed sensor wiring -2-
- Remove securing pins -1-
- Unbolt vehicle speed sensor wiring -2- Remove securing pins -1-
- Remove wiring from axle beam -3-
- Disconnect ABS vehicle speed sensor from wheel bearing housing
These two steps are for vehicles with automatic headlight range control ONLY:
- Remove nut -arrow A- and bolt -arrow B- from coupling rod -1- for vehicle level control system sensor -2-
- Pull out coupling rod -1- in -direction of arrow-
- Set engine/transmission jack -V.A.G 1383A- equivalent under rear final drive
- Remove axle beam bolts
- Lower sub frame using engine/transmission jack -V.A.G 1383A- or equivalent
- Remove right rear wheel well liner -1- by unscrewing seven bolts -3-
- Remove shielding plate for fuel filler tube
- Clean area surrounding fuel filler tube
- Unscrew mounting bolt for fuel flap and remove fuel flap unit with rubber gasket
- Remove securing bolts from filler neck
- Disconnect supply line -1- from fuel filter
- Mark return hose -2- and breather hose -3- and separate at connecting point
- Seal lines so the fuel system is not contaminated with debris
- Remove cover from EVAP canister
- Disconnect ventilation lines at EVAP canister -arrows-
- Remove tensioning straps and support fuel tank using engine/transmission jack -V.A.G 1383 A- or equivalent, if not already done
- Lower fuel tank and proceed to Section H