All Wheel Drive
Fuel Tank
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Engine-/Gearbox Jack (V.A.G 1383 A)
Removing
• The rear subframe must be removed in order to be able to remove the fuel tank.
• Read the safety precautions before starting. Refer to => [ Safety Precautions ] Fuel Supply.
• Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.
• Fuel tank overview. Refer to => [ Fuel Tank and Attachments Overview ] Fuel Tank and Attachments Overview.
- Drain the fuel tank if necessary using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
- Remove the rear seat bench.
- Remove the cover - 1 - and the fuel pump control module - 2 - from the fuel delivery unit.
- Disconnect the 5 pin connector - arrow - from the flange.
Fuel Level Sensor 2 Cover Side
- Disconnect the connector to the all wheel drive control module - 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 and vacuum lines - arrows - from the Evaporative Emission (EVAP) canister.
- Unclip the electrical wire on the fuel filler tube - arrows -.
- Remove the tank flap unit bolts and remove the unit.
- Remove the fuel filler tube bolts - arrows -.
- Remove the center muffler together with both rear mufflers. Refer to => [ Muffler and Mounts Overview ] Muffler and Mounts Overview.
- Secure the front exhaust pipe to the tunnel bridge with wire - arrow -.
- Remove the rear subframe.
The fuel supply line is under pressure. Always wear protective eye wear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.
- Disconnect the fuel line (black) and the vent line (white). Also disconnect the vacuum line (green) - C -.
• Press the locking ring to unlock 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 bolts - arrows -. Support the fuel tank using the engine-/gearbox jack (V.A.G 1383 A) beforehand.
- Slowly the lower fuel tank.
• The fuel tank must removed between the body and driveshaft. To do so, lift the fuel tank with help from a second mechanic, down from the engine-/gearbox jack (V.A.G 1383 A).
Installing
- Make sure the wire - arrows - for the all wheel drive control module is clipped to the fuel tank.
- Two technicians are needed to guide the fuel tank back up in between the driveshaft and body. Then place the fuel tank on the engine-/gearbox jack (V.A.G 1383 A).
- Lift the fuel tank slowly up to it's installed position and install the bolts - arrows -.
• Only use bolts with loose washers to secure the straps. The straps could twist when the bolts are tightened if other bolts are used. For the correct bolts, refer to the Parts Catalog
- Install the rear subframe.
- Connect the connector - A - and the fuel line - B -. Check the fit by pulling on it.
Further installation is in the reverse sequence to removal. When doing this note the following:
- Note the location of the covers - arrows -:
The - 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 secure.
• Check the fuel tank/body ground connection on 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
