Fuel Tank, From 07.07

Fuel System Components

Fuel Tank, from 07.07

• Vehicles from 07.07 have a one piece driveshaft. The rear subframe must be completely removed on these vehicles.

• Fuel tank, removing and installing, through 06.07. Refer to => [ Fuel Tank, through 06.07 ]. Fuel Tank, Through 06.07

Special tools, testers and auxiliary items required

• Torque Wrench (5 to 50 Nm) (V.A.G 1331)

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

Removing

• Rear the rear subframe must be removed in order to be able to remove the fuel tank.

• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.

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

• Fuel tank and components overview. Refer to => [ Fuel Tank and Components Overview ] Fuel Tank and Components Overview.

- Drain the fuel tank as necessary using (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

- Remove the rear seat bench.

- Remove the cover - 1 - with fuel pump control module (J538) - 2 - from the fuel delivery unit.





- Disconnect the 5 pin connector - arrow - from the flange.





On the fuel level sensor 2 (G169) cover:

- Disconnect the connector from the all wheel drive control module (J492) - arrow -.





- Remove the grommet - 1 - from the cover and guide the all wheel drive control module wiring harness downward and out.

- Remove the cover - 1 - and disconnect the 3 pin connector - arrow - from the flange.





- Remove the right rear wheel.

- Remove the right rear wheel housing liner.





- Disconnect the vent lines and vacuum line - arrows - from the Evaporative Emission (EVAP) canister.





- Unclip the electrical wire - arrows - from the fuel filler tube.

- Remove the fuel filler door unit.

- Remove the fuel filler tube to body bolts - arrows -.





- Remove the center muffler together with both rear mufflers. Refer to => [ Front Exhaust Pipes with Catalytic Converters and Front Mufflers ] Front Exhaust Pipes With Catalytic Converters and Front Mufflers.

- Secure the front exhaust pipe to the tunnel bridge with wire.





- Remove the rear subframe.

CAUTION!
The fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then carefully disconnect the connection to release the pressure.

- Disconnect the fuel line, ventilation line and vacuum line - A, B and C - at the connection point.





• Press in the securing ring to disengage the fuel line.

- Lay the driveshaft on the tunnel bridge - arrow -. The maximum bending angle for the driveshaft is maintained by the tunnel bridge.





- Remove the fuel tank securing strap/fuel tank bolts - arrows -. Support the fuel tank using (V.A.G 1383 A) beforehand.





- Slowly lower the fuel tank.

• The fuel tank must removed between the body and driveshaft. To do so, lift the fuel tank with help from a second technician, down from the (V.A.G 1383 A).

Installing

- Make sure the wire for the all wheel drive control module is clipped to the fuel tank - arrows -.





- Two technicians are needed to guide the fuel tank back in between the driveshaft and body. Then place the fuel tank onto the (V.A.G 1383 A).

- Lift the fuel tank slowly up to the installed position and install the securing strap/fuel tank bolts - arrows -.





• To secure the fuel tank straps, only bolts with loose washers may be used. If other bolts are used, the straps could twist when the bolts are tightened.

- Install the rear subframe.

- Connect the connector - A - and the fuel line - B -. Check the fit by pulling on it.





Further installation is performed in reverse order. When doing this note the following:

- Note the location of the covers - arrows -:





- Arrows - on the covers must point in the direction of travel.

A Fuel delivery unit cover
B Fuel level sensor 2 cover

• Make sure the vent and fuel lines are not kinked.

• Pull on the line connections to make sure they are securely connected.

• Check the ground (GND) connection for the fuel tank/chassis at the filler tube.

• If the fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump, refer to "Guided Functions" in the vehicle diagnostic tester.

Tightening Specifications