Fuel Tank, Removing And Installing, Vehicles With 3.0L (V6)/4.2L (V8) Engines: 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 .
-- Open the fuel filler door.
-- Turn off the ignition and remove the key.
Vehicles from 11/2006:
-- 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 right 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 .
-- Vehicles with parking heater: Disconnect the fuel line to the parking heater. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .
Continuation for All Vehicles
-- Open the fuel tank flap.
-- Clean the area around the fuel filler tube.
-- Remove the fuel cap -arrow-.
-- Seal off the fuel filler tube opening with a clean plug to prevent dirt from getting in.
-- Remove the fuel filler door insert, refer to FUEL FILLER DOOR, REMOVING AND INSTALLING .
-- Pry out rubber gasket -1- and remove it outward.
-- 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 (110 lbs)).
-- 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 (7.8 in).
-- Remove the right rear wheel housing liner, refer to Wheel Housing Liners .
-- Disconnect the Ground (GND) wire -1- from the fuel filler tube.
-- Remove the bolts -2 and 3- from the fuel filler tube.
-- Remove the nuts -arrow- and the fuel filler tube shield.
-- Drive pins -1- through with a punch.
-- Remove bracket -2- with vent lines from longitudinal member.
Vehicles through 10/2006
-- Disconnect fuel pump and fuel level sensor connectors -1 and 2- on the left longitudinal member.
Continuation for All Vehicles
-- 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 .
-- Unclip the fuel supply line -2- and the fuel return line -3- from the fuel tank and from the bracket -arrows-.
-- Unclip parking brake cable bracket -4- at fuel tank.
-- Vehicles with parking heater: Also unclip fuel supply line -1- to auxiliary heater metering pump.
-- Place the Engine/Gearbox JackVAG1383A with the Subframe Support T10031 (without threaded rods) under the fuel tank to support it as shown.
- The Subframe Support T10031 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 bolts -1 to 12- and remove 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.
Vehicles through 10/2006:
Place a clean cloth under the separating location to catch any fuel that may leak out.
-- Thread through gap between body and fuel tank.
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 the fuel lines -1 and 3-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .
-- Vehicles with parking heater: Disconnect the fuel line -2- to the parking heater. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .
Continuation for All Vehicles
-- Lower the fuel tank with the Engine/Gearbox JackVAG1383A while a second technician guides it.