Fuel tank with attachments, removing and installing

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2008 Audi S4, 2008 Audi RS 4, 2008 Audi A4, 2007 Audi S4, and 2007 Audi RS 4. However, it is still accessible from the selected car via links, so may be relevant.

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 cap briefly and then close again.

Sedan:

Remove carpeting in luggage compartment.
Fold forward the 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: Identifying Locking Flange Electrical Harness Connectors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 6: Disconnecting Ventilation Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate ventilation line - 1 -. Do this by pressing the releasing ring - 2 - approx. 2 mm in direction - arrow A - and simultaneously pulling ventilation line - arrow B - off.
Open tank flap and clean the area around fuel filler tube.

NOTE:

Do not remove fuel cap.

Fig 7: 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 8: 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 bolts - 1 - for fuel filler tube.

Fig 9: 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 10: Removing Ventilation Lines

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig 11: Removing Vehicle Floor Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cover for vehicle floor - arrows -.

Fig 12: Removing Covers For Vehicle Floor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove covers - 1 - and - 2 - for vehicle floor.
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
.

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: Disconnecting Right Parking Brake Cable At Front Of Fuel Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect right parking brake cable at front of fuel tank at areas indicated with - 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 14: Separating Ventilation Line And Fuel Line From Right Front Of Fuel Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect ventilation line - 2 - and fuel line - 1 - from right front of 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 15: Identifying Fuel Tank Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 through 7 -.
Lower fuel tank using engine/transmission jack V.A.G 1383 A.

Installing

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

Fig 16: Identifying Fuel And Ventilation Lines Are Properly Clipped To Fuel Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Make sure fuel and ventilation lines are properly clipped to fuel tank - arrows -.
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.

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 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.

First tighten fuel tank at securing points - 2, 5, 3, 4 - and then at - 1, 6, 7 -.
Fasten fuel filler tube.

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

Specification: approx. 0 Ohm.

Install rear axle → 42 - REAR SUSPENSION .
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 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
Tension straps at body		23
Fuel filler tube to body		23
EVAP canister cover		9