Fuel Tank, Removing, TDI Vehicles

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Special tools and workshop equipment required

Trim Removal Wedge:3409 or
Scraper no. 1 from the Scraper Set:VAS6845
Engine and Gearbox Jack:VAS6931
Gearbox Support:T40173

Removing

-- Pay attention to all safety precautions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

-- Switch off the ignition.

WARNING:

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 .

-- Remove the right bench seat / single seat. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

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-- Fold the insulation over the sealing flange cover to the side.

-- Unclip the sealing flange cover -1- at the tabs, in direction of -arrows-, using either the :3409 or the scraper from :VAS6845 .

-- Disconnect the connectors -1 and 3- on the sealing flange by unlocking the connector safety catch.

Fig 1: Fuel Pump Connectors

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-- Country/Rest of World equipment versions: release the connector safety catch and disconnect the connector -2-.

-- Remove the right rear wheel housing liner. Refer to REAR WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Remove the fuel filler door unit. Refer to FUEL FILLER DOOR UNIT, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and remove the reducing agent tank filler neck -1- from the fuel filler neck. Refer to the appropriate service information .

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-- Remove the fuel filler neck bolts -arrows-.

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NOTE:

Seal the fuel filler neck opening with a clean plug to prevent any dirt from getting in.

-- Remove the rear underbody trim panels. Refer to REAR UNDERBODY TRIM PANEL, REMOVING AND INSTALLING .

-- Remove the rear section of the exhaust system. Refer to OVERVIEW - MUFFLER .

-- Remove the driveshaft. Refer to the appropriate service information .

-- Remove the subframe. Refer to OVERVIEW - SUBFRAME .

-- Country/Rest of World equipment versions: loosen the lock washer and remove the fuel hose -1- to the parking heater.

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-- Disconnect fuel lines -2 and 3-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Attach the :T40173 to the :VAS6931 and position it to support the fuel tank, as shown.

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WARNING:

Risk of accident due to the weight of the fuel tank.

The fuel tank must be empty when removing it.

-- Remove the bolts -1 through 7-.

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NOTE:

For reasons of clarity, the fuel tank is shown without the engine and gearbox jack.

-- Lower the fuel tank using the :VAS6931 .

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NOTE:

When guiding out the fuel tank, pay attention to the clearance to the fuel filler neck.