Front Wheel Drive (FWD)
Fuel Tank With Attachments, Removing And Installing
Special tools and required equipment
- VAG1383 A with VAG1359/2
Removing
- Obtain radio code on vehicles with coded radio/integrated radio.
- Remove cover above battery -arrow-.
NOTE: On vehicles without battery cover: Remove plenum cover.
- With ignition switched off, disconnect battery Ground (GND) strap -arrow-
- Open fuel filler cap briefly and close again.
Limousine:
- Remove cover for sender for fuel gauge located under liner in luggage compartment.
- If necessary; fold the right rear seat back forward.
Avant:
- Remove cover for sender for fuel gauge located under liner in luggage compartment.
All:
- Remove cover -arrow- for fuel tank sender.
- Carefully release 4-pin harness connector for sender for fuel gauge in direction of -arrow- and disconnect.
- Thoroughly clean area around fuel filler neck.
- With the fuel filler flap open, loop -1- where available.
- Pry locking collar -arrow- in the rubber cup (around the filler neck) out.
- Push rubber cup inward.
- Open fuel filler cap briefly and close again.
NOTE: Do not remove caps.
- Remove right rear wheel housing unit.
- Remove bolt -1- for fuel filler neck.
- Disconnect line -2- to EVAP canister and unclip line from retainer -arrow-.
- Remove cover in front of rear axle -arrows-.
Vehicles with level control system
- Remove level control system sensor -G84- at body -arrows-.
All:
WARNING: Fire hazard. Fuel system is under pressure. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
- Disconnect fuel supply and return lines -arrows-.
- Position VAG1383A Engine/Transmission jack for support under fuel tank.
WARNING: The fuel tank must be empty when removing in order to reduce weight. If necessary empty fuel tank.
- If necessary, mark retaining straps for easier re-installation.
- Remove fasteners -1- through -6- and remove fuel tank support straps, if necessary mark straps for later installation.
- Lower fuel tank using VAG 1383A engine/transmission jack while turning it to left.
NOTE: -Arrow- points toward the front of the vehicle.
Installing
Installation is the reverse of removal, however note the following:
NOTE:
- Replace all hose clamps with the same type of clamp that was used in production.
- Use VAG 1921 pliers or similar tool to install spring clamps.
- Always replace seals and O-rings.
- Make sure that return and supply lines at right-front side of fuel tank are secured in retainer -arrows-.
- Route and connect Ground wire -arrow- as shown.
- Make sure that harness connector for Ground (GND) connection is properly seated on metal ring (Ground clamp) on fuel filler neck.
- Check if contact terminal (tongue) at fastening hole is properly locked in.
- Hold terminal tongue -1- with bolt -2- to fuel filler neck.
CAUTION:
After installing the expansion tank, use ohmmeter to check the electrical connection between metal (Ground clamp) ring on the fuel filler neck and bare metal part (Ground (GND) on Body.
- Specification: approx. 0 Ohm
- After tightening fuel tank support straps, press cap -1- onto screw -2- in spare wheel well.
- With ignition switched off, reconnect battery Ground (GND) strap.
NOTE: Carefully install the cover for the plenum chamber under the windshield to prevent water from entering the pollen filter or the heater.
- After reconnecting battery, insert radio code.
NOTE:
- Using switches, fully close power windows up to stop.
- Then, operate all power windows for at least 1 second in "close" position to activate "one touch" opening/closing function.
- Set time on clock.
- Generate readiness code.
Tightening torques
Component Tightening torque
Tank straps at body 23 Nm (17 ft lb)
Fuel filler neck to body 23 Nm (17 ft lb)
Cover for rear axle 10 Nm (7 ft lb)
Battery Ground strap to battery 5 Nm (44 in. lb)
Level control system sensor to body 10 Nm (7 ft lb)