Fuel tank with attachments, removing and installing

Special tools, testers and auxiliary items required

Fig 1: Engine/Transmission Jack V.A.G 1383 A

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Engine/transmission jack V.A.G 1383 A

Fig 2: Support T10031

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Support T10031

Removing

Observe safety precautions → Safety precautions .

Observe rules for cleanliness → Rules for cleanliness .

CAUTION:

For removal, fuel tank must be empty for weight reasons. Empty fuel tank if necessary. Procedure → Fuel tank, emptying .

Release fuel tank flap.

CAUTION: Observe safety precautions when disconnecting the battery → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Fig 3: Removing Cover Of Right Luggage Compartment Side Trim

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Remove cover of right luggage compartment side trim - arrows -.

Fig 4: Removing Cover Above Battery

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Remove cover - 1 - above battery.

NOTE:

Ignore - 2 -.

Fig 5: Disconnecting Battery Ground (GND) Strap

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Fig 6: Removing/Installing Cover For Right Locking Flange

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Remove trim for luggage compartment floor.
Remove for right locking flange - arrows -.

Fig 7: Disconnecting Vent Line By Pressing Releases

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Disconnect vent line - arrow - by pressing releases.

CAUTION: Before removing the subframe bolts, secure the vehicle against tipping over (e.g. load the luggage compartment with approx. 50 kg).

Remove rear axle → 42 - REAR SUSPENSION .
Remove right rear wheel housing liner → 66 - EXTERIOR EQUIPMENT .

Fig 8: Identifying Ground (GND) Wire, Fuel Tank Lock Switch F314 Electrical Connector, Fuel Filler Tube Vent Line & Bolts

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Disconnect Ground (GND) wire - 3 - from fuel filler tube.
Disconnect electrical connector - 1 - for Fuel Tank Lock Switch F314.
Disconnect vent line - 5 - from fuel filler tube.
Remove bolts - 2 - and - 4 - for fuel filler tube.

Make sure driveshaft is secured from falling down.

Fig 9: Setting Driveshaft On Wooden Block And Securing With Wire Or Cable

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The driveshaft must be set on a wooden block - 1 - and be secured with wire or cable - arrow -.
Make sure that the driveshaft is angled slightly downward so that the fuel tank can later be guided over this and out during removal.

NOTE:

The max. allowable angle of the driveshaft must not exceed 8°.

Fig 10: Removing Heat Shield For Driveshaft

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Remove heat shield for driveshaft - arrows -.

NOTE:

The heat shield is also clipped in at the top to the vent line.

Fig 11: Removing Left Cover From Bottom Of Vehicle Floor

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Remove left cover - 1 - from bottom of vehicle floor.

Fig 12: Removing Right Cover From Bottom Of Vehicle Floor

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Remove right cover - 1 - from bottom of vehicle floor.

Fig 13: Identifying Electrical Harness Connectors

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Disconnect electrical harness connectors:

2 - To fuel pumps

3 - To fuel gauge sensors

Separate fuel lines by pressing release buttons:

1 - Fuel return line

4 - Fuel supply line

Fig 14: Disconnecting Right Rear Vent Line On Fuel Tank By Pressing Release Button

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Disconnect right rear vent line - arrow - on fuel tank by pressing release button.

Fig 15: Attaching Brake Calipers To Struts With Wire

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The brake calipers, that were previously hung on fuel tank brackets when rear axle was removed, must now be attached to struts with wire - arrow -.

Fig 16: Supporting Fuel Tank Using Engine/Transmission Jack V.A.G 1383 A And Support T10031

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Place Engine/transmission jack V.A.G 1383 A with support T10031 (without threaded rods) under fuel tank for support.
Support fuel tank using engine/transmission jack V.A.G 1383 A and support T10031.
A second technician must also support fuel tank by hand at rear edge.

Fig 17: Removing/Installing Bolts & Pivot Fuel Tank Brackets Forward

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

Remove bolts - 1 to 6 - and if necessary, pivot fuel tank brackets forward.
Lower fuel tank toward rear slightly so that the fuel filler tube can be guided out of body.
Lower fuel tank using Engine/transmission jack V.A.G 1383 A , guiding it by hand.

NOTE:

To improve clarity, the fuel tank is shown without Engine/transmission jack.

Installing

Tightening torques → Fuel tank with attachments, assembly overview .

Fig 18: Identifying Brackets & Backing Pieces

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Check whether fuel lines and wiring harness to fuel pumps and fuel level sensors are clipped on brackets - 1 - on fuel tank.
When installing a new fuel tank, paste backing pieces - 2 - onto fuel tank, as shown in the illustration.
Position fuel tank with mounting straps and brackets to vehicle floor using engine/transmission jack V.A.G 1383 A and support T10031.
Make sure fuel tank is positioned so that the filler tube can be correctly guided into opening of body.

Fig 19: Removing/Installing Bolts & Pivot Fuel Tank Brackets Forward

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Fasten fuel tank to fastening points - 1 - , - 2 - , - 5 - , - 6 - first, and then to - 3 - and - 4 -.

Fig 20: Making Sure Spacer Of Securing Straps Is Seated Directly Below Seam Of Fuel Tank

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Make sure that the spacer of securing straps is seated directly below seam of fuel tank - arrow -.

Fig 21: Identifying Ground (GND) Wire, Fuel Tank Lock Switch F314 Electrical Connector, Fuel Filler Tube Vent Line & Bolts

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Fasten fuel filler tube using bolts - 2 - and - 4 -.
Push vent line - 5 - on until it engages audibly.
Connect electrical connector - 1 - for Fuel Tank Lock Switch F314.
Check if Ground (GND) wiring - 3 - and contact show signs of oxidation. If necessary, remove.

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

Specified value: approx. 0 Ω.

The rest of installation is in reverse order of removal, note the following:

NOTE:

Replace seals and gaskets when performing repair work.
Secure all hose connections using hose clamps appropriate for the model type .

Install rear axle → 42 - REAR SUSPENSION .
Install right rear wheel housing liner → 66 - EXTERIOR EQUIPMENT .
Install rear part of exhaust system →
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.
Connect battery. Observe safety precautions after connecting battery → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .