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
.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
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 4: Unbolting Cover For Locking Flange In Luggage Compartment

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 5: Disconnecting Ventilation Line

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

Fig 6: Removing Cover Bolts For Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 7: Identifying Right Locking Flange Electrical Harness Connectors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - 1 - at right locking flange.
Disconnect electrical connector - 2 -.

Fig 8: 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 9: 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 the inside.
Remove right rear wheel.
Remove right rear wheel housing liner →
- 66 EXTERIOR EQUIPMENT
- 66 - EXTERIOR EQUIPMENT for BODY EXTERIOR - CABRIOLET
.

Fig 10: Removing Ventilation Line From Fuel Filler Tube & Bolts For Fuel Filler Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 11: 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 12: Removing Ventilation Lines

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect 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 -.
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 13: Removing Heat Shields

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove heat shields - 1 - and - 2 -.

Fig 14: Disconnecting Parking Brake Cables

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 15: Disconnecting Fuel Line And Right Ventilation Line From Fuel Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect fuel line - 1 - and right ventilation line - 2 - 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 16: 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.

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 Ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.
Check installation position of Ground (GND) connection:

Fig 17: Installation Position Of Ground (GND) Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The connector - 4 - must be securely attached to metal ring - 3 -.
The 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 the body.

Fig 18: 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 fuel filler tube screws →
- 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