Fuel Tank, Removing And Installing, Vehicles With 3.0L (B6) Engine With Reducing Agent Metering System: Removing
Follow all safety precautions, refer to WORKING ON FUEL SYSTEM .
Follow the guidelines for clean working conditions, refer to CLEAN WORKING CONDITIONS .
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 .
-- On a vehicle with air suspension, activate vehicle lift mode, refer to VEHICLE LIFT MODE .
-- Turn off the ignition and remove the key.
Danger due to reducing agent leaking out.
- To prevent large amounts of reducing agent from leaking out when opening the metering line, wait for the recirculation process of the reducing agent to complete, refer to WORKING ON REDUCING AGENT METERING SYSTEM, VEHICLES WITH SCR CATALYTIC CONVERTER .
-- Remove the left single seat and the left 2/3 seat bench seat cushion in the second row of seats, refer to Seat Frames .
-- Remove the right rear single seat in the second row of seats, refer to Seat Frames .
Risk of injury.
- Wear safety gloves
-- Cut the floor covering along the perforation -arrows- on the left and right sides with a carpet knife -1-.
-- Fold carpet cut-out to side -arrow-.
-- Remove the left and right nuts on the locking flange cover -1 ••• 4- and then remove the cover.
-- Disconnect the connector -arrow- on the left locking flange.
-- Disconnect the connector -4- on the right locking flange.
-- If equipped, disconnect the connector -3- on the locking flange.
Place a clean cloth under the separating location to catch any fuel that may leak out.
Very hot fuel can burn your skin.
- In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
- Wear safety gloves
- Wear protective eyewear.
There is a risk of injury because the fuel is under pressure.
- To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.
-- Disconnect fuel lines -1 and 2-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .
-- Open the fuel tank flap.
-- Clean the area around the fuel filler tube.
-- Remove the locking cap -1- from the fuel filler tube.
-- Remove the locking cap -2- from the reducing agent filler tube.
Seal the openings on the filler tube with clean plugs to prevent dirt from possibly getting into the chambers.
-- Remove the tank door unit and the rubber buffer, refer to Remove the Tank Flap Unit .
-- Remove the fuel filler tube bolts -arrows-.
Risk of vehicle tipping on hoist with rear axle removed.
- Secure the vehicle on a hoist before loosening the subframe bolts (for example, load the luggage compartment with about 50 kg).
-- Remove the rear axle, refer to REAR AXLE OVERVIEW .
-- Hang driveshaft -1- on body with a suitable chain or with welding wire as shown in illustration -arrows-.
Driveshaft CV joints must only be moved without force and only as far as stop which is approximately a 10° angle.
-- Lower driveshaft by dimension -a-.
- Dimension -a- = 220 mm.
-- Remove the right rear wheel housing liner, refer to Wheel Housing Liners .
-- Remove the reducing agent active tank, refer to REDUCING AGENT ACTIVE TANK, REMOVING AND INSTALLING .
-- Disconnect the Ground (GND) wire -1- from the fuel filler tube.
-- Remove the fuel filler tube bolts -arrows-.
-- Remove the nuts -arrows- and then remove the fuel filler tube protective plate -3-.
-- Drive pins -1- through with a punch.
-- Remove the bracket -2- with the lines from the longitudinal member.
-- Remove the left and right bolts on the floor panel trim near the fuel tank, refer to FRONT AND REAR DOOR TRIM MOLDING, REMOVING AND INSTALLING .
-- Remove the reducing agent passive tank, refer to REDUCING AGENT ACTIVE TANK, REMOVING AND INSTALLING .
Place a clean cloth under the separating location to catch any reducing agent that may leak out.
The reducing agent can cause skin irritation.
- Avoid contact with skin and eyes! Always wear protective gloves and safety glasses.
- If reducing agent should get on your skin, wash it off immediately with soap and water.
- If reducing agent gets in your eye, rinse the eye for several minutes with water.
- Never inhale or swallow the reducing agent!
- Should you swallow any reducing agent, rinse your mouth, drink plenty of water and contact a doctor immediately.
-- Disconnect the metering line -2-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .
-- Disconnect the connector -1-.
-- Unclip the fuel supply line -1- and the fuel return line -2- on the fuel tank -arrows-.
-- Unclip the parking brake cable bracket -3- from the fuel tank.
-- Place the Engine/Gearbox JackVAG1383A with the Subframe SupportT10031 (without threaded rods) under the fuel tank to support it as shown.
- The Subframe SupportT10031 mounting plates must be positioned near the round impressions in the bottom of the fuel tank.
-- Support the fuel tank with the Engine/Gearbox Jack VAG1383A and the Subframe Support T10031.
-- A second technician must also support fuel tank by hand.
-- Identify location of fuel tank securing bands.
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 10- and remove the securing bands and carrier plate.
To improve clarity, the fuel tank is shown without the Engine/Gearbox JackVAG1383A.
-- Next lower back of fuel tank to driveshaft.
-- A second technician is needed to hold the rear edge of the fuel tank.
-- Carefully guide filler tube out of wheel housing so avoid paint damage.
-- Lower the fuel tank with the Engine/Gearbox JackVAG1383A while a second technician guides it.