AWD

Fuel Tank, Removing And Installing

Special tools, testers and auxiliary items required







- Engine/transmission jack V.A.G 1383 A







- Torque wrench V.A.G 1331

NOTE:
- The fuel tank must not be more than 1/3 full.
- Empty fuel tank if necessary.
- Read safety precautions system and rules of cleanliness before beginning work.

Removing
- Open fuel flap and remove fuel tank cap.
- Check whether a coded radio is installed. If necessary, obtain radio anti-theft coding.
- Switch off ignition and switch off all electrical consumers.
- Disconnect battery Ground (GND) strap, See Electrical Equipment, - Repair Group 27.
- Remove rear seat bench.
- Remove cover from fuel delivery unit.







- Disconnect 4-pin connector from flange at fuel tank - arrow -.
- Remove center and rear mufflers of exhaust system, removing.
- Remove subframe, See Suspension, Wheels, Steering - Repair Group 42.
- Remove right rear wheelhousing liner, See Body Exterior - Repair Group 66.
- Remove shielding plate for fuel filler tube.
- Clean area surrounding fuel filler tube.
- Unscrew mounting bolt for fuel flap and remove fuel flap unit with rubber cap.
- Remove securing bolts on filler neck.

CAUTION: Fuel supply lines are under pressure. Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.







- Disconnect supply line -1- from fuel filter.
- Mark return hose -2- and breather hose - 3. and separate at connecting point.
- Seal lines so that fuel system is not contaminated by dirt etc.
- Remove shielding plates at left and right on fuel tank and on underbody.
- Remove cover from EVAP canister.







- Disconnect ventilation lines at EVAP canister - arrows -.
- Seal lines so that fuel system is not contaminated by dirt etc.
- Remove tensioning strap. Support fuel tank using engine/transmission jack V.A.G 1383 A while doing so.
- Lower fuel tank.

Installing
Installation is performed in reverse order of removal. Note the following:
- Make sure ventilation and fuel lines are not kinked when installed.
- Ensure fuel hoses are seated securely.
- Fuel lines must be secured with clamps Parts catalog "ETKA".
- Do not swap supply and return lines (return line: blue lettering, supply line: white lettering).

NOTE: After installing fuel tank, check that the supply, return and breather lines are still clipped onto the fuel tank.

- Check Diagnostic Trouble Code (DTC) memory of all control modules, repair all stored malfunctions, and erase DTC memory Vehicle Diagnosis, Testing and Information System VAS 5051; Guided Fault Finding; Vehicle System Test, or Vehicle Diagnosis and Service Information System VAS 5052; On Board Diagnostic (OBD).