All Wheel Drive (AWD) Vehicles
Fuel tank with attachments, removing and installing
Special tools and equipment
^ VAG 1383A with VAG 1359/2
Removing
Observe safety precautions.
Observe rules for cleanliness.
Note: For weight reasons, fuel tank must be emptied for removal.
^ Note radio code (for vehicles equipped with coded anti-theft radio). Obtain if necessary.
Vehicles equipped with 4-cylinder engine
^ If installed, remove cover above battery.
^ Open battery protective casing (Velcro).
^ Switch ignition off and disconnect battery Ground (GND) strap (arrow).
Vehicles equipped with 6-cylinder engine
^ Switch ignition off and disconnect battery Ground (GND) strap (arrow)
TT Coupe:
^ Remove rear seat bench.
TT Roadster:
^ Remove the rear panel side trim.
All:
^ Unscrew cover-1- at right (arrows).
^ Disengage 4-pin electrical harness connector (arrow) and remove.
^ Open fuel flap.
^ Clean area surrounding fuel filler unit.
^ Remove fuel filler cap from fuel filler unit.
^ Remove center and rear muffler of exhaust system:
^ Remove drive shaft:
^ Remove rear axle:
^ Remove right-rear wheel housing liner:
^ Unscrew Ground (GND) wire -2- and screws -1- for fuel filler unit.
WARNING: Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
^ Disconnect return line -1- (blue) supply line -2- (black) and vent line -3(white) front right at fuel tank (press release button).
Note: Electric wire to Leak Detection Pump (LDP) -V144- will not be disconnected.
^ Disconnect vent lines -1- and -2- to EVAP canister.
^ Place VAG1 383A engine/transmission lifter under fuel tank for retrieval.
WARNING: For weight reasons, fuel tank must be emptied for removal.
^ Loosen screws as follows:
- Retaining tabs -1- and -5-.
- Carrier panel -3- and -7-.
- Mounting straps -2-, -4-, -6- and -8-.
^ Lower fuel tank.
Installing
Installation is the reverse of removal, noting the following:
Note:
^ Secure all hose connections with the correct hose clamps (same as original equipment.
Refer to Parts Supplier
^ To secure spring-loaded hose clamps, use hose clamp pliers VAG 1921.
^ Check the ground wiring at both ends for traces of oxidation. Remove any traces of oxidation if necessary.
^ Route the Ground (GND) wire as shown.
^ Make sure connector -2- is seated properly on metal ring -1- of fuel filler opening.
^ Engage Ground (GND) connection at both retaining clips (arrows).
Note:
^ The illustration depicts Ground (GND) wire routing when fuel tank is removed.
^ Depending on construction version, a cable binder may be implemented in place of a clip.
^ Position fuel tank with carrying sheet and mounting straps at vehicle floor using VAG1383A engine/transmission lifter.
^ Secure fuel tank using bolts as follows:
- Mounting straps -2-, -4-, -6- and -8-.
- Carrier panel -3- and -7-.
- Retaining tabs -1- and -5-.
^ Tighten bolts -1- and screw on Ground (GND)connection -2-.
WARNING:
^ After installing, check electrical Ground connection using ohmmeter between fuel pump delivery unit and chassis.
^ Specified value: 0 Ohms
^ Check installation position of rubber cup.
^ Install rear right wheel housing liner and tighten fastening bolt for fuel filler neck:
^ Install drive shaft:
^ Install rear axle:
^ Install and adjust (tension free) center and rear muffler of exhaust system.
Note:
^ After connecting battery, be sure to activate the electrical accessories (radio, clock, power windows).
^ Generate readiness code.
Tightening torques