Fuel Tank With Attachments: Removing
Follow all safety precautions. Refer to SAFETY PRECAUTIONS .
Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .
-- On a vehicle with air suspension, activate vehicle lift mode. Refer to VEHICLE LIFT MODE .
-- Open the fuel filler door.
Risk of destroying electronic components when disconnecting the battery.
- Observe measures for disconnecting battery.
-- Disconnect the battery. Refer to BATTERY .
Risk of injury due to fuel tank weight.
- Fuel tank must be empty to remove.
-- Empty fuel tank. Refer to FUEL TANK, DRAINING .
Risk of vehicle tipping on hoist with rear axle removed.
- Before removing the subframe bolts, secure the vehicle (for example load the luggage compartment with approximately 50 kg).
-- Remove rear axle. .
-- Hang driveshaft -1- on the 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.
-- 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 the fuel filler door insert. .
-- Pry out rubber gasket -1- and remove it outward.
-- Remove the bolts -arrows- for fuel filler tube.
-- Remove the right rear wheel housing liner. Refer to REAR WHEEL HOUSING LINERS, REMOVING AND INSTALLING .
-- Disconnect the vent lines -1 and 2-.
-- Remove the vacuum line -3- from the Leak Detection Pump -V144-.
-- Disconnect Ground (GND) wire -4- from fuel filler tube.
-- Remove the bolts -5 and 6- from the fuel filler tube.
-- Remove fuel filler tube protective plate -arrows-.
-- Drive pins -1- through with a punch.
-- Remove bracket -2- with vent lines from the longitudinal member.
-- Remove the sill panel cover bolts marked with an -arrow- on the left side of the underbody.
-- Remove the sill panel cover bolts marked with an -arrow- on the right side of the underbody.
-- Unclip lines -1 to 3- at fuel tank and bracket -arrows-.
-- Unclip parking brake cable bracket -4- at the fuel tank.
-- Disconnect fuel pump and fuel level sensor electrical connectors -1 and 2- at left longmember.
-- Place the Engine - Transmission Jack VAG 1383 A with Support T10031 (without threaded rods) under fuel tank for support, as shown in the illustration.
- The Support T10031 mounting plates must be positioned near the round impressions in the bottom of the fuel tank.
-- Support fuel tank with Engine - Transmission Jack VAG 1383 A and T10031.
-- A 2nd technician must also support the fuel tank by hand.
-- Identify location of fuel tank securing bands.
Risk of injury due to fuel tank weight.
- The fuel tank must be empty when removing it.
-- Remove bolts -1 through 12- and remove securing bands and carrier plate.
To improve clarity, the fuel tank is shown without the Engine - Transmission Jack VAG 1383 A.
-- Next lower back of fuel tank to driveshaft.
-- A second technician must also support the fuel tank by hand at the rear edge.
-- Carefully guide filler tube out of the wheel housing so to avoid paint damage.
-- Thread through gap between body and fuel tank.
Risk of injury from fuel.
- To reduce residual pressure remaining in the fuel system, lay a clean cloth around the connector and carefully loosen connector.
-- Disconnect fuel line -3- by pressing release buttons.
-- Disconnect ventilation line -1- and vacuum line -2- by pressing the release buttons.
-- Lower fuel tank using Engine - Transmission Jack VAG 1383 A while a 2nd technician guides it.