Fuel Tank, Removing and Installing

WARNING!
Fire hazard. When working on the fuel system DO NOT smoke, work near heaters or have anything in the area that can ignite the fuel or fumes.
Fuel supply lines are under pressure! Before loosening any lines, cover the connection with a rag. Release the pressure by slowly disconnecting connection.

Special tools, test equipment and auxiliary items
- VAG 1359/2 fixture
- VAG 1383A engine/transmission jack
- VAG 1433A fuel cart

Removing (all-wheel drive vehicles)
- Observe safety precautions.
- Observe rules of cleanliness.





- Pull rubber gasket off toward front (arrow).
- Remove plenum chamber cover -1- toward front





- With ignition switched off, disconnect battery Ground (GND) strap (arrow).

CAUTION!
Before disconnecting the battery, determine the correct coding for the anti-theft radio.
Because of weight and safety considerations make sure that the fuel tank is empty before removing it.

NOTES:
Before starting to work on the fuel Supply system, briefly open the fuel filler cap and close it again.
If necessary, empty the fuel tank using VAG 1433A fuel cart or similar approved equipment.

- Remove rear seat bench.
- Remove cover for closing flange on right-side under rear seat bench.





- Carefully release 4-pin harness connector in direction of arrow and disconnect.
- Remove center and rear mufflers.
- Remove heat shield for fuel filler neck above rear muffler.
- Remove rear axle.
- Remove right-rear wheel housing liner.
- Clean around fuel filler neck.
- Open fuel filler flap, remove retaining ring and rubber cup surrounding filler neck.
- Push out rubber cup toward inside.





- Remove 2 bolts (arrows) for fuel filler neck underneath wheelhousing liner.
- Disconnect line -1- to EVAP canister.





- Mark supply line -3-, return line -2- and vent line -1- and disconnect.





- Disconnect vent line for EVAP canister (arrow) at rear of fuel tank.

NOTE: The vent line remains attached when the fuel tank is removed.

- Remove heat shields at left and right of fuel tank.
- Support fuel tank using VAG 1383A engine/transmission jack.





- Remove fasteners -1- through -8- for support straps and carrier panel.
- Lower fuel tank together with carrier panel -9-.

NOTE: The arrow points toward the front of the vehicle.

Installing (all-wheel drive vehicles)

Installation is the reverse of removal, however note the following:

NOTES:
- Replace all hose clamps with the same type of clamp that was used in production.
- Use VAG 1921 pliers or similar tool to install spring clamps.
- Always replace seals and O-rings.
- Identification of lines: return lines are blue or have blue stripes and the supply lines are black.

WARNING Make sure that both of the terminals for Ground connection make good electrical contacts.

- Mount the terminal with the bolt (item -12- ) for fuel filler neck.
- After installing, measure the resistance using a multimeter (Fluke 83 or equivalent) between the metal ring of the fuel filler neck and a bare metal part of the body. Specified value: approx. 0 Ohms

- Make sure that fuel pressure and return lines at right-front of fuel tank are properly installed in retainers.
- Carefully install cover for closing flange with indentation positioned on top of connector.
- With ignition switched off, reconnect battery Ground (GND) strap.
- After reconnecting battery, insert radio code again.

NOTE: Carefully install the cover for the plenum chamber under the windshield to prevent water from entering the pollen filter or the heater.

- Using switches, fully close power windows up to stop.
- Operate all power windows for at least 1 second in "close" position to activate "one touch" opening/closing function.
- Set time display on clock.

Torque specifications

Component Tightening torque
Tank straps at body 25 Nm (18 ft lb)
Fuel filler neck to body 25 Nm (18 ft lb)
Heat shield for fuel filler neck 2 Nm (18 in. lb)
Battery Ground strap to battery 5 Nm (44 in. lb)