Fuel tank with attachments, removing and installing

Special tools, testers and auxiliary items required

Fig 1: Identifying Engine/Transmission Jack V.A.G. 1383 A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine/transmission jack V.A.G 1383 A

Removing

Observe safety precautions → Safety precautions when working on fuel supply system .

Observe rules for cleanliness → Rules for cleanliness .

CAUTION:

For removal, fuel tank must be empty for weight reasons. Drain fuel tank if necessary. Procedure → Fuel tank, draining .

CAUTION:

Observe procedures for disconnecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

All except Audi RS4:

Fig 2: Pushing Cover Over Battery Toward Right And Removing It Upward

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push cover over battery toward right - arrow 1 - and remove it upward - arrow 2 -.

Fig 3: Locating Battery Ground Strap

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

Audi RS4:

Remove carpeting in luggage compartment.

Fig 4: Disconnecting Battery Ground (GND) Strap

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

All:

Open fuel filler flap briefly and then close again.

Sedan:

Remove carpeting in luggage compartment.
Fold forward right rear seat backrest, if necessary.

Wagon:

Remove left 1/3 backrest →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.
Remove left side luggage compartment trim and dirt tray →
- 70 - INTERIOR TRIM
- 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
.

All models:

Fig 5: Unbolting Cover For Locking Flange In Luggage Compartment

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Unbolt cover for locking flange in luggage compartment - arrows -.

Fig 6: Disconnecting Ventilation Line

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Separate ventilation line - 1 -. Do this by pressing the releasing ring - 2 - approx. 2 mm in direction of - arrow A - and simultaneously pulling ventilation line off - arrow B -.
Remove rear seat bench →
- 72 - SEAT - FRAMES
- 72 - SEAT - FRAMES for BODY INTERIOR - CABRIOLET
.

Fig 7: Removing Cover Bolts For Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt cover for locking flange, left and right - arrows -.

Audi RS4:

Fig 8: Removing Electrical Wires With Connector From Locking Flange Opening

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Remove electrical wires with connector - arrow - from locking flange opening and lay them aside.

All:

Fig 9: Disconnecting Electrical Harness Connector At Right Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - at right locking flange.

Fig 10: Disconnecting Electrical Harness Connector At Left Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - at left locking flange.
Open tank flap and clean area around fuel filler tube.

NOTE:

Do not remove fuel cap.

Fig 11: Opening Tank Flap And Cleaning Area Around Fuel Filler Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pry tensioning ring - arrow - out from rubber gasket and press rubber gasket through toward inside.
Remove right rear wheel.
Remove right rear wheel housing liner →
- 66 EXTERIOR EQUIPMENT
- 66 - EXTERIOR EQUIPMENT for BODY EXTERIOR - CABRIOLET
.

Fig 12: Removing Ventilation Line From Fuel Filler Tube & Bolts For Fuel Filler Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull ventilation line - 2 - off from fuel filler tube by pressing release buttons.
Remove bolt - 1 - for fuel filler tube.

Fig 13: Removing EVAP Canister Cover At Bottom Of Spare Wheel Well

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove EVAP canister cover at bottom of spare wheel well - arrows -.

Fig 14: Removing Ventilation Lines

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Separate ventilation lines - 1 - and - 2 -. Do this by pressing releasing ring - 3 - in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
Unclip ventilation lines - A - at top from bracket - arrow -.

Audi RS4:

Fig 15: Removing Bolts & EVAP Canister Cover At Bottom Of Spare Wheel Well

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Remove bolt - 1 -.
Remove EVAP canister cover at bottom of spare wheel well - arrows -.
Disconnect purge lines - 1 - and ventilation lines - 2 - by pressing the release button.

Fig 16: Unclipping Lines From Bracket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unclip lines from bracket - arrow -.

All:

Remove rear part of exhaust system →
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
- 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF
.
Remove drive shaft →
- 39 FINAL DRIVE, DIFFERENTIAL
- 39 - FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE 0AR
.

CAUTION: Before removing the subframe bolts, secure the vehicle against falling over (e.g. load the luggage compartment with approx. 50 kg).

Remove rear axle → 42 - REAR SUSPENSION .

Fig 17: Removing Heat Shields

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Remove heat shields - 1 - and - 2 -.

Fig 18: Disconnecting Parking Brake Cables

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Disconnect parking brake cables at positions indicated by - arrows -.

CAUTION: The fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.

Fig 19: Separating Fuel Line And Ventilation Line At Right Front From Fuel Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate fuel line - 2 - and ventilation line - 1 - at right front from fuel tank, by pressing release buttons.
Place engine/transmission jack V.A.G 1383 A under fuel tank for support.

CAUTION:

For weight reasons, fuel tank must be empty for removal.

Fig 20: Identifying Fuel Tank Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 through 10 -.
Lower fuel tank using engine/transmission jack V.A.G 1383 A by guiding it by hand.

Installing

Installation is in reverse order of removal. Note the following:

Make sure fuel and ventilation lines are properly clipped to fuel tank.
Check if the Ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
Check installation position of Ground (GND) connection:

Fig 21: Installation Position Of Ground (GND) Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connector - 4 - must be securely attached to metal ring - 3 -.
Contact - 1 - must be attached into fuel tank - 5 - and be secured with spacer bushing - 2 -.

Position fuel tank with mounting straps and carrier plate to vehicle floor using engine/transmission jack V.A.G 1383 A.
Make sure fuel tank is positioned so that the filler tube can be correctly guided into opening of body.

Fig 22: Identifying Fuel Tank Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten mounting straps and carrier plate - 1 through 10 -.
Fasten fuel filler tube.

CAUTION: After installing, check electrical connection of metal ring at fuel filler tube to a blank portion of chassis using Ohm meter:

Specification: approx. 0 Ohm.

Install rear axle → 42 - REAR SUSPENSION .
Install drive shaft →
- 39 FINAL DRIVE, DIFFERENTIAL
- 39 - FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE 0AR
.
Install rear part of exhaust system →
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
- 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
- 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF
.
Install right rear wheel housing liner, thereby fastening the bolt for fuel filler tube →
- 66 EXTERIOR EQUIPMENT
- 66 - EXTERIOR EQUIPMENT for BODY EXTERIOR - CABRIOLET
.

Connect battery. Observe safety precautions after connecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

Torque specifications

Component		Nm
Mounting straps and carrier plate for fuel tank to body		23
Fuel filler tube to body		23
EVAP canister cover		9
Audi RS4: EVAP canister cover	Nut	2.3
	Bolt	2