Fuel Tank, Removing, TDI Vehicles

Special tools and workshop equipment required 

• Trim Removal Wedge:3409  or
  Fig 1: Identifying Trim Removal Wedge

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• Scraper no. 1 from the Scraper Set:VAS 6845 
  Fig 2: Identifying Clip release lever no. 4 from the Scraper Set VAS6845

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• Engine and Gearbox Jack:VAS 6931 
  Fig 3: Engine and Gearbox Jack VAS6931 or VAG1383A

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• Gearbox Support:T40173 
  Fig 4: Gearbox Support T140173

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Removing

-- Pay attention to the safety precautions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

-- Switch off the ignition.

-- Drain the fuel tank. Refer to FUEL TANK, DRAINING .

-- Remove the bench seat / right single seats. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

-- Fold the insulation over the sealing flange cover to the side.

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-- Unclip the sealing flange cover -1- at the tabs -arrows- using either the Trim Removal Wedge:3409  or the scraper from the Scraper Set Scraper Set:VAS 6845  .

-- Disconnect the connectors -1 and 3- on the sealing flange by unlocking the connector safety catch.

Fig 5: Fuel Pump Connectors

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-- Country/Rest of World equipment versions: release the connector safety catch and disconnect the connector -2-.

-- Remove the right rear wheel housing liner. Refer to REAR WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Remove the fuel filler door unit. Refer to FUEL FILLER DOOR UNIT, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and remove the reducing agent filler neck -1- from the fuel filler neck. Refer to the appropriate Service Information. .

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-- Remove the fuel filler neck bolts -arrows-.

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-- Remove the rear underbody trim panels. Refer to REAR UNDERBODY TRIM PANEL, REMOVING AND INSTALLING .

-- Remove the rear section of the exhaust system. Refer to MUFFLER, REMOVING AND INSTALLING - 2.0L DMSA , MUFFLER, REMOVING AND INSTALLING - 2.0L DPVA , MUFFLER, REMOVING AND INSTALLING - 3.0L .

-- Remove the driveshaft. Refer to the appropriate Service Information. .

-- Remove the subframe. Refer to OVERVIEW - SUBFRAME .

-- Country/Rest of World equipment versions: loosen the lock washer and remove the fuel hose -1- to the parking heater.

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-- Disconnect the fuel lines -2 and 3-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Conditions

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• Use the Gearbox Support:T40173  with the mount chromated in yellow and the joint element -B- or with valid CE symbol -A-.

-- Attach the Gearbox Support:T40173  to the Engine and Gearbox Jack:VAS 6931  and position it to support the fuel tank, as shown.

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-- Remove the bolts -1 through 7-.

-- Lower the fuel tank using the Engine and Gearbox Jack:VAS 6931  .

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