Removing and installing fuel tank, front-wheel drive — VW

Removing and installing fuel tank, front-wheel drive
Special tools and workshop equipment required
Torque wrench (5…50 Nm)
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
Removing
Note
Before carrying out further work, disconnect the battery. For this reason, first check whether a coded radio is fitted. Obtain anti-theft coding beforehand if necessary.
When lowering fuel tank, guide it carefully to prevent damage.
Disconnect battery earth strap with ignition switched off
Rep. gr.
27
Battery; Disconnecting and connecting battery
.
Empty fuel tank as far as possible via fuel filler neck using
fuel extractor
VAS 5190
Chapter
“
Emptying fuel tank
”
.
Unclip rubber cup from filler neck.
Unscrew bolts
3
on filler neck
1
.
Remove rear left wheel.
Remove rear left wheel housing liner
General body repairs, exterior
Rep. gr.
66
Wheel housing liner; Removing and installing rear wheel housing liner
.
On Caddy Maxi, unscrew bolt
arrow
for filler neck on side member.
Remove rear silencer
Rep. gr.
26
Exhaust pipes/silencers; Removing and installing rear silencer
.
If fitted, remove heat shield.
WARNING
The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!
Wear eye and hand protection when performing any type of repair work on the fuel system!
Separate fuel lines
1
and
2
at front right of fuel tank
Chapter
“
Separating plug-in connectors
”
.
On vehicles with auxiliary heater, detach fuel line
1
from hose
2
on metering pump
Rep. gr.
82
Fuel supply;
Removing and installing metering pump
V54
Support fuel tank with
engine and gearbox jack
V.A.G 1383 A
.
Unscrew bolts
arrows
and remove tensioning straps
2
.
Slowly lower
engine and gearbox jack
V.A.G 1383 A
until 5-pin connector can be pulled off the fuel delivery unit.
Continue to lower fuel tank
1
. In the process, turn fuel tank and guide filler neck between leaf spring and body.
Installing
Install in reverse order. In the process, note the following:
Caution
The fuel pump must not be allowed to run when the fuel tank is empty, as this may cause deflagrations.
The fuel tank must contain at least 5 litres of fuel.
If fitted, check that
metering pump
V54
is firmly seated.
Install breather and fuel lines free of kinks.
Make sure that the filler neck of the fuel tank is correctly inserted into the opening in the body.
Position the fuel tank together with securing strap on underbody, using the
engine and gearbox jack
V.A.G 1383 A
.
Note position of securing strap.
After installing fuel tank, check that the supply, return and breather lines are still clipped onto the fuel tank.
Make sure bracket for exhaust system is seated correctly
Rep. gr.
26
Exhaust pipes/silencers; Assembly overview - silencers
.
Ensure that line connections are tight.
Ensure connections are secured properly by pulling.
Check whether there are signs of oxidation on the earth wire of the connectors, remove if necessary.
Check installation position of earth connection.
Ensure that connector
2
is seated securely on metal ring
3
.
Contact tab
1
must be hooked into fuel tank
4
and secured by means of spacer bush
5
.
Check the connection of the metal ring on the fuel filler neck by measuring between the ring and a bare metal part of the body using an ohmmeter.
Specification: approx. 0 ohm.
If the specification is not attained, there is a risk of explosion due to electrostatic discharge.
Fill fuel tank with at least 5 litres of fuel.
Specified torques
Fuel tank
Chapter
“
Assembly overview - fuel tank
”
Rep. gr.
26
Exhaust pipes/silencers; Assembly overview - silencers
General body repairs, exterior
Rep. gr.
55
Tank flap unit; Removing and installing tank flap unit