With FWD as of 11.04

With FWD as of 11.04

=> [ Fuel Tank with Attachments ]

=> [ Fuel Delivery Unit ]

=> [ Fuel Level Sensor ]

Fuel Tank with Attachments

Special tools, testers and auxiliary items required

• Engine/Transmission Jack (V.A.G 1383 A )

Removing

Observe safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.

Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.

CAUTION!
• For removal, fuel tank must be empty for weight reasons. Empty fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Service and Repair.

CAUTION!
• Observe safety precautions when disconnecting the battery.

- Push the cover over the battery toward the right - arrow 1 - and remove it upward - arrow 2 -.

- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.

- Open fuel filler flap briefly and then close again.

Sedan:

- Remove carpeting in luggage compartment.

- Fold forward the right backrest of rear seat, if necessary.

Wagon:

- Remove left 1/3 backrest.

- Remove left side trim in luggage compartment and dirt tray.

All:

- Remove cover - arrows - for locking flange in luggage compartment.

- Disconnect electrical harness connector - arrow - at locking flange.

- Disconnect ventilation line - 1 -. Do this by pressing the releasing ring - 2 - approximately 2 mm in direction - arrow A - and simultaneously pulling the vent line off - arrow B -.

- Open the tank flap and clean the area around the fuel filler tube.

• Do not remove fuel cap.

- Pry the tensioning ring - arrow - out from rubber gasket and press the rubber gasket through toward the inside.

- Remove right rear wheel.

- Remove right rear wheel housing liner.

- Pull vent line - 2 - off from fuel filler tube by pressing the release buttons.

- Unfasten the bolt - 1 - for fuel filler tube.

- Remove EVAP canister cover at bottom of spare wheel well - arrows -.

- Separate the vent lines - 1 - and - 2 -. Do this by pressing the releasing ring - 3 - in direction - arrow A - and simultaneously pulling the vent line off - arrow B -.

- Unclip the vent lines at top from the bracket - arrow -.

- Remove vehicle underbody cover - arrows -.

- Remove the vehicle underbody covers - 1 - and - 2 -.

- Remove rear part of exhaust system.

CAUTION!
Before removing the subframe bolts, secure the vehicle against tipping over (e.g. load the luggage compartment with approximately 50 kg).

- Remove rear axle.

- Unhook right parking brake cable at front of fuel tank at the areas indicated with - arrows -.

- Place the Engine/Transmission Jack (V.A.G 1383 A ) under the fuel tank for support.

CAUTION!
• For weight reasons, fuel tank must be empty for removal.

- Remove bolts - 1 to 7 -.

- Lower the fuel tank with the Engine/Transmission Jack (V.A.G 1383 A).

Installing

Installation is in reverse order of removal, note the following:

- Make sure the fuel and vent lines are properly clipped to the fuel tank - arrows -.

- Check if the Ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.

- Check the installation position of the Ground (GND) connection:

• The connector - 4 - must be securely attached to the metal ring - 3 -.

• The contact - 1 - must be attached into the fuel tank - 5 - and be secured with the spacer bushing - 2 -.

- Position the fuel tank with mounting straps to vehicle floor using the Engine/Transmission Jack (V.A.G 1383 A).

- Make sure the fuel tank is positioned so that the filler tube can be correctly guided into the opening of the body.

- First tighten fuel tank at securing points - 2, 5, 3, 4 - and then at - 1, 6, 7 -.

- Fasten the fuel filler tube.

CAUTION!
After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter:

• Specified value: Approximately 0 ohms.

- Install rear axle.

- Install rear part of exhaust system.

- Install right rear wheel housing liner by tightening fuel filler neck screws.

- Connect battery. Observe safety precautions after connecting battery.

Tightening Specifications

Fuel Delivery Unit

Special tools, testers and auxiliary items required

• Wrench (T10202)

Removing

Observe safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.

Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.

CAUTION!
• To remove the fuel delivery unit, the fuel tank may only be filled to a maximum of 3/4. Empty fuel tank if necessary. Refer to => [ Fuel Tank, Draining ] Service and Repair.

• Observe safety precautions when disconnecting the battery.

- Push the cover over the battery toward the right - arrow 1 - and remove it upward - arrow 2 -.

- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.

Sedan:

- Remove carpeting in luggage compartment.

- Fold forward the right backrest of rear seat, if necessary.

Wagon:

- Remove left 1/3 backrest.

- Remove left side trim in luggage compartment and dirt tray.

All:

- Remove cover - arrows - for locking flange in luggage compartment.

- Disconnect electrical harness connector - arrow - at locking flange.

- Mark the fuel supply line - 1 - and fuel return line - 2 -.

CAUTION!
Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.

- Pull both lines from locking flange, by pressing the release buttons.

CAUTION!
Fuel delivery unit may only be removed when fuel tank is maximum 3/4 filled. Otherwise, a large amount of fuel will spill out.

- Remove locking ring with Wrench (T10202).

- Lift the fuel delivery unit slightly out of the fuel tank opening and remove the seal.

- If fuel delivery unit is still inserted in fuel tank, slide locking flange slightly to the side.

- Reach through the gap between locking flange and installation opening in fuel tank and pull off the suction jet line - 1 - from the suction jet pump, by pressing release button.

- Release the suction jet pump - arrows - and remove it.

- Remove fuel delivery unit.

• When removing fuel delivery unit, be sure not to bend floater arm of Fuel Level Sensor (G).

• Be aware that fuel is still in the fuel delivery unit.

Installing

Installation is in reverse order of removal, note the following:

• Replace seal.

• When installing fuel delivery unit, be sure not to bend floater arm of Fuel Level Sensor (G).

• Ensure fuel hoses are seated securely.

- Insert fuel delivery unit into fuel tank.

- Clip in suction jet pump on fuel delivery unit. To do so, insert hand into gap between locking flange and installation opening of fuel tank.

• Suction jet pump must engage audibly.

- Verify that the suction jet pump is securely engaged.

- Push the suction jet pipe - 1 - onto connection of the suction jet pump until it engages audibly.

- Install the new locking flange seal dry.

- Press locking flange down against spring pressure and bring it into installation position.

• Tab - 2 - on locking flange must lie between tabs - 1 - and - 3 - on fuel tank.

• - Arrow - points in direction of travel.

- Tighten locking ring.

- Install fuel supply line - 1 - and fuel return line - 2 - according to the marking.

- Connect electrical harness connector.

- Connect battery. Observe safety precautions after connecting battery.

- Fill vehicle with at least 5 liters of fuel after installing fuel level sensor.

- After replacing fuel delivery unit, there should be a fuel pump adaptation on vehicles with 4-cyl. TFSI engine. Refer to => [ Fuel Pump Adaptation after Replacing Fuel Delivery Unit, Vehicles with 4-Cyl. TFSI Engine ] Vehicles With Front Wheel Drive as of 11.2004.

Tightening Specifications

Fuel Level Sensor

Removing

Observe safety precautions. Refer to => [ Safety Precautions ] Fuel Supply System.

Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.

- Remove fuel delivery unit. Refer to => [ Fuel Delivery Unit ].

- Release the retaining tabs - arrows - with a screwdriver and pull the Fuel Level Sensor (G) upward and out.

CAUTION!
Before removing electrical connectors on Fuel Level Sensor (G), first release contact retaining tabs.

- Disengage electrical connector retaining tabs - 1 - and - 2 - and disconnect them.

Installing

Installation is in reverse order of removal, note the following:

- Connect the electrical connections - 1 - and - 2 - and check that they are securely engaged.

- Insert Fuel Level Sensor (G) in the guides on the fuel delivery unit and push down until it engages.

- Install fuel delivery unit , observing notes for connecting battery.