Fuel Tank, Removing, TDI Vehicles

Special tools and workshop equipment required 

• Engine and Gearbox Jack :VAS6931 
• Gearbox Support :T40173 

Removing

-- Follow 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.

-- Drain the fuel tank. Refer to FUEL TANK, DRAINING .

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

-- Remove the bolts -arrows- and remove the sealing flange cover -1-.

Fig 1: Sealing Flange Cover

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

Fig 2: 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 OVERVIEW - PLENUM CHAMBER COVER .

A4:

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-- Remove the bolts -1- and remove the reducing agent tank filler neck -3- from the fuel filler neck. Refer to the appropriate service information .

-- Remove the fuel filler neck bolts -2-.

A5:

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

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

Continuation for All Vehicles:

-- Disengage the fuel filler neck from the mount.

-- Remove the rear underbody trim panels. Refer to OVERVIEW - UNDERBODY TRIM PANELS .

-- Remove the rear section of the exhaust system. Refer to MUFFLER, REMOVING AND INSTALLING [CWGD] / MUFFLER, REMOVING AND INSTALLING [CYMC] .

-- Rest of World market-specific version/equipment version: loosen the lock washer -2- and remove the fuel hose -3- from the metering pump -1-.

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-- Disconnect fuel lines -1 and 2-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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FWD Vehicles:

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

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-- Remove the bolts -1 to 5-.

-- Lower the fuel tank using the Engine and Gearbox Jack :VAS6931  .

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AWD Vehicles:

-- Equipped on some models: remove the diagonal brace. Refer to DIAGONAL BRACES, REMOVING AND INSTALLING .

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

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

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-- Remove the bolts -1 through 7-.

-- Lower the fuel tank using the Engine and Gearbox Jack :VAS6931  .

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