Fuel Tank, Removing And Installing, Vehicles With Torsion Beam Axle: Removing

WARNING: This page is about a different variant/trim than selected.

NOTE:

Observe the safety instructions. Refer to SAFETY PRECAUTIONS .

-- Move the front seats all the way forward.

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

-- Turn off the ignition and all electrical equipment and remove the key.

-- Open the fuel filler door and the fuel cap.

-- Fold the carpet up at the right in the area of the fuel delivery unit.

-- If equipped, remove the cover -1- and Fuel Pump Control Module -J538- -2- from the fuel delivery unit.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

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-- Unclip the cover -1- at the tabs in direction of -arrows- using the : 3409 .

Fig 2: Identifying Right Cover

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-- Disconnect the connector -arrow- from the fuel delivery unit.

Fig 3: Fuel Pump Control Module Connector

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

Vehicles with EVAP Canister Installed in the Right Rear Wheel Housing

-- Disconnect all lines from the EVAP canister to the filler neck. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Continuation for All Vehicles

-- Remove the bolts -1 and 2- from the filler tube.

Fig 4: Identifying Bolts

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-- Remove the ABS line -arrows- from the retainers.

-- Disconnect the vent line -1- (white) and supply line -2- (black) at the connecting point. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 5: Disconnecting Vent Line (White) And Supply Line (Black) At Connecting Point

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-- Loosen the clamping sleeve -9-.

Fig 6: Identifying Muffler, Twist Beam Suspension Components Overview

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NOTE:

A second technician is required for the remainder of the procedure to help support the exhaust system.

-- Remove the rear section of the exhaust system from the body and lay it on the torsion beam Axle.

The exhaust system is then hanging by the rear axle and the rear tunnel brace.

-- Push the exhaust system as far as possible to the left.

-- Remove the mounting strap and bolts -arrows-. Have a second technician hold the fuel tank -1- while doing this.

Fig 7: Identifying Mounting Strap And Bolts

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Always make sure there is enough clearance for the filler neck to prevent damaging the fuel tank while removing it.

-- Move the fuel tank from the rear downward once it is removed from the rear axle. While doing this turn the fuel tank to the left.

-- Remove the fuel tank downward. While doing this turn the fuel tank slightly to the left. The filler neck can then be guided past the rear axle.