Removal and Replacement

Fuel Tank and Attachments

CAUTION!
During all repair procedures on the fuel tank, be aware of the following:

• Route all the various lines (e.g. for fuel, Evaporative Emission (EVAP) system, or vacuum) and electrical wiring so that the original routing positions are restored.

• Make sure that the ground (-) strap between the fuel filler tube and body is securely fastened, to prevent electrostatic charging.

• Ensure sufficient clearance to all moving or hot components.

Special tools, testers and auxiliary items required

• Torque wrench (5 to 50 Nm) (VAG 1331)

• Engine and transmission jack (VAG 1383 A)

Requirements

• The fuel tank must be drained. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

Removing

- Read safety precautions before beginning work. Refer to => [ Safety Precautions ] Safety Precautions.

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

- Fold rear seat bench forward. On vehicles from 12.06, rear seat bench must be removed. Refer to

- Cut open the carpet on the right side from point - A - to point - B - in the precut area - arrow -.





- Remove the nuts - 1 - from the right side fuel delivery unit cover. If necessary, remove backrest support - 2 - or mounting bracket. Refer to





CAUTION!
Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before disconnecting connection, wrap a cloth around the connection. Then release pressure by carefully separating connection.

- Remove fuel supply line - 1 -, auxiliary heater fuel line - 2 -, fuel pump connector - 3 -, vent line - 4 - and Fuel Pump (FP) control module (J538) connector - 5 -.





• Press in securing ring to disengage the fuel line.

- Remove mufflers and mountings. Refer to => [ Muffler and Mounts Assembly Overview ] Description and Operation.

- Remove driveshaft.

- Remove rear drive axle.

- Open fuel door and remove fuel cap.

- Pull rubber gasket off filler neck.

- Remove bolts - 1 - for filler neck and disconnect ground (GND) wire - 2 -.





- Remove right rear wheel housing liner.

- Unbolt cover plate - arrow -.





- Unclip fuel tank breather lines at clip attached on longitudinal member.





- Remove bolts for filler pipe - 1 - and EVAP canister - 2 - in wheel housing.





- Bend filler neck slightly downward and pull off breather line connections to EVAP canister.





• Release connection by pressing button on hose coupling.

- Disconnect GND wire clipped to EVAP canister and remove canister.

- Disconnect fuel pump connectors, on the left next to the fuel tank.





- Remove straps with covers on the left and right below the fuel tank.

- Support fuel tank using the engine and transmission jack (VAG 1383 A) and remove strap at center of fuel tank.

- Carefully lower fuel tank about 30 cm.

- Grab between fuel tank and vehicle floor and disconnect vent line from left sensor flange.

• This step eliminates having to cut open the carpeting in the vehicle interior in the vicinity of sender flange cover.

- Lower fuel tank.

Installing

Installation is performed in the reverse order of removal, noting the following:

• Connections for breather and fuel lines must engage audibly when joined.

• Make sure ventilation and fuel lines are not kinked when installed.

• The flange seal should be replaced each time it is opened.

• Secure fuel hoses with spring type clamps.

• Ensure fuel hoses are seated securely.

• The ground strap at the fuel filler tube - 2 - must be securely connected to the body.





• Before fastening the fuel tank, check that the supply and ventilation lines are still clipped onto the fuel tank.