Contents: Petrol models ⬇ Diesel models ⬇
Petrol models
Note: The description is given using the 1.8 and 2.0 l models as an example.
1. The installation details of the fuel tank and its components are shown in the accompanying illustrations.
11.1 Fuel tank installation details and its components (petrol models)
1 Fuel supply line, black
2 Return fuel line, blue
3 Sealing ring, replaceable, inserted dry, lubricated with fuel only the inner flange seal (for installation)
4 Fuel supply module, with fuel reserve sensor "G"
5 Retaining ring, 110 Nm
6 Block "J538" fuel pump control, after replacement ECM adaptation is required
7 Fuel tank cap
8 Fixing screw
9 Assembling the neck, with a rubber cup
10 Body mass connection
11 Bolt, 11 Nm
12, 16, 17 Ventilation line
13 Sensor wiring connector 14
14 Sensor No.2 "G169" fuel reserve
15 Suction jet pump, fixed to the sensor body 14
18 Fuel tank
19 Clamp
20 Bolt, 25 Nm, subject to replacement
21 Bolt, 23 Nm
22 Heat shield, riveted together with the exhaust pipe hanger
23 Bolt, 3 Nm
24 Fuel filter
25 Ventilation line, mounted on the side of the tank
2. Empty the tank and disconnect the devices used for this purpose (see Section 3).
3. On models before 06.2010, remove the cover of sensor No.2 "G169" and disconnect its connector (right arrow in the accompanying illustration).
11.3 Fuel tank wiring connectors
4. Clean the filler neck and the surrounding area, then open it and seal it with a sponge to prevent dirt from entering.
5. Remove the rear right wheel and rear right wheel arch liner. Unscrew the bolts (1 on the accompanying illustration) filler neck, unhook the electrical wiring from the bracket (2) at the top and bottom of the neck.
11.5 Neck fastening
6. Disconnect the white vent line (1 on the accompanying illustration) and the black supply line (2). On models with additional heater, additionally disconnect the supply line of the metering pump "V54".
11.6 Connecting Node
7. Remove the rear cross member of the central tunnel (see accompanying illustration). Unhook the rear muffler from the two clamps, loosen the double clamp nuts and unscrew the rear exhaust pipe hanger bolts. Remove the rear muffler.
11.7 Rear tunnel cross member
8. On all-wheel drive models, remove the propeller shaft (see Chapter 8), disconnect the connector of the "J492" block with all-wheel drive, release its wiring (arrows in illustration 11.9) and set aside.
9. Remove the bolts (2 and 6 in the accompanying illustration), support the tank with a transmission jack, remove the bolts (1, 3, 4 and 6) and lower the tank a little. With the help of an assistant, remove the tank from the jack, passing the filler neck between the body and the rear suspension.
11.9 Fuel tank fastening
10. Before installation, check and, if necessary, remove corrosion from both ground connections. Ground wire (1 on the accompanying illustration) must be securely attached to the ring (2)\ contact (4) must hang on the tank (3) and must be secured using the spacer sleeve (5).
11.10 Ground connection on tank
11. Installation is carried out in the reverse order. Arrow (2 in illustration 3.18) on the lid should be facing forward.
Diesel models
12. The installation details of the fuel tank and its components are shown in the accompanying illustration using the TDI-CR models as an example.
11.12 Fuel tank installation details and its components (tDI-CR diesel models)
1 Assembly of the neck, with a rubber cup
2 Fuel tank cap
3 Support part
4 Body mass connection
5 Bolt, 10 Nm
6 Jet pump
7 Retaining ring, 110 Nm
8 Sensor No.2 "G169" fuel reserve
9 Seal, subject to replacement
10 Fuel tank
11 Clamp
12 Bolt, subject to replacement, 25 Nm
13 Bolt, 25 Nm
14 Heat shield
15 Fuel supply module, with fuel reserve sensor "G"
16 Fuel supply line, black, to fuel filter
17 Return fuel line, blue, from fuel filter