Fuel Tank With Attachments, Removing And Installing

Fuel Tank With Attachments, Removing And Installing

Special tools and equipment







- VAG1383A with VAG1359/2

Removing
Observe safety precautions.
Observe rules for cleanliness.

NOTE: For weight reasons, fuel tank must be emptied for removal.

- Note radio code (for vehicles with coded anti-theft radio). Obtain if necessary.

Vehicles 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 with 6-cylinder engine







- Switch ignition off and disconnect battery Ground (GND) strap (arrow) under trunk floor.

TT Coupe
- Remove rear seat bench.

TT Roadster
- Remove the rear panel side trim.

Continued for all vehicles







- Unscrew cover-1- at right (arrows).







- Disengage 4-pin electrical harness connector (arrow) and remove carefully.
- Open fuel flap.
- Clean area surrounding fuel filler unit.
- Remove fuel filler cap from fuel filler unit.
- Remove rear axle.
- Remove center and rear muffler of exhaust system.







- Remove mounts -1- and -2- for rear muffler.
- Remove heat shield for rear muffler (arrows).
- Remove right rear wheelhousing 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: Electrical wire to Leak Detection Pump (LDP) -V144- will not be disconnected.







- Disconnect vent lines -1- and -2- to EVAP canister.
- Place VAG1383A engine/transmission lifter under fuel tank for retrieval.

CAUTION: For weight reasons, the fuel tank must be emptied for removal.







- Loosen screws (arrows). Begin at retainer strap (lower left arrow).
- 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).
- To secure spring-loaded hose clamps, use hose clamp pliers VAG 1921.

- Check ground wiring at both ends for traces of oxidation. Remove any traces of oxidation if necessary.







- Route 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 and mounting straps at vehicle floor using VAG1383A engine/transmission lifter.







- Secure fuel tank at mounting points (arrow) using bolts (26 Nm).
- Bolt mounting straps first.







- Tighten bolts -1- and screw on Ground (GND) connection -2-.

WARNING:
- After installing, check electrical Ground connection using ohm meter between fuel pump delivery unit and chassis.
- Specified value: 0 Ohm

- Check installation position of rubber cup.
- Install rear right wheelhousing liner and tighten fastening bolt for fuel filler neck:
- Install and adjust (tension free) center and rear muffler of exhaust system.
- Install rear axle:

NOTE:
- After connecting battery, be sure to activate the electrical accessories (radio, clock, power windows).
- Additional precautions for reconnecting the power supply:

- Generate readiness code.

Tightening torques

Components Nm

Mounting straps for fuel tank to chassis 26 Nm
Fuel tank to chassis 26 Nm
Fuel filler unit to bracket 11 Nm
Ground (GND) wire at wheelhousing 10 Nm
Battery terminal to battery post 5 Nm