Fuel Tank

WARNING: This page is about a different car, the 2008 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Torque wrench (5-50 Nm) VAG 1331
Engine and transmission jack VAG 1383A

Removing

-- Read the safety precautions before beginning work. Refer to SAFETY PRECAUTIONS .

Empty the fuel tank if necessary using the VAS 5190. Refer to FUEL TANK, DRAINING .

-- Remove the mounting bolt for the fuel flap unit and remove the fuel flap unit. Refer to Removal and Installation .

-- Remove the right rear wheel.

-- Remove the rear right wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

-- Disconnect the vacuum line -1-.

Fig 1: Identifying Vacuum Line -1-, Leak Detection Pump (LDP) Electrical Harness Connector -2-, Vent Line -3- And Nuts -Arrows-

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-- Disconnect the electrical connector -2-.

-- Disconnect the vent line -3-.

-- Remove the nuts -arrows-.

-- Remove the Leak Detection Pump (LDP) pump with bracket.

-- Remove the vent line -1- to the Evaporative Emission (EVAP) canister by pressing the release button.

Fig 2: Identifying Vent Line To Evap Canister -1-, Electrical Wire -2- And Bolts -Arrows-

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-- Unclip the vent line from the bracket.

-- Remove the electrical wire -2- for the Anti-lock Brake System (ABS) speed sensor from the fuel filler tube bracket.

-- Remove the bolts -arrows- for the fuel filler tube.

-- Disconnect the vent line -arrow- to the EVAP canister by pressing the release button.

Fig 3: Identifying Vent Line To EVAP Canister

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-- Remove the rear seat bench. Refer to Removal and Installation .

-- Remove the covers and disconnect the electrical connectors -arrows-.

Fig 4: Identifying Electrical Connectors

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CAUTION:

To protect the decoupling elements, secure the front part of the exhaust system to the vehicle underbody with wire before removing the mufflers.

-- Remove the center and rear mufflers.

-- Remove rear driveshaft. Refer to RIGHT FLANGE SHAFT .

-- Disconnect the vent lines -1- (white) and -3- (green) from the right front of the fuel tank, by pressing the release button.

Fig 5: Identifying Vent Lines & Fuel Line

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WARNING:

Fuel system is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

-- Disconnect the fuel line -2- (black) from the fuel filter by pressing the release button.

-- Disconnect the adapter wire on the All Wheel Drive (AWD) control module.

Fig 6: Identifying Adapter Wire Connected To All-Wheel Drive Control Module J492

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-- Remove the tensioning straps and bolts. Support the fuel tank using the VAG 1383A beforehand.

Fig 7: Identifying Tensioning Bands And Mounting Bolts

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-- Slowly lower the fuel tank.

NOTE:

Fuel filler tube must be removed between the chassis and rear subframe. To do so, lift the fuel tank with a second mechanic down from the VAG 1383A.

Installing

-- Clip the AWD control module wire to the fuel tank.

Fig 8: Identifying All-Wheel Drive Control Module J492 Wire Clipped On Fuel Tank

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-- With a second mechanic assisting, guide the fuel filler tube between the rear axle and chassis. Then place fuel tank onto the VAG 1383A.

-- Lift the fuel tank slowly up to the installed position and secure it -arrows-.

Fig 9: Identifying Tensioning Bands And Mounting Bolts

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-- Connect the adapter wire to AWD control module.

Fig 10: Identifying Adapter Wire Connected To All-Wheel Drive Control Module J492

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Further installation is performed in reverse order. When doing this note the following:

Make sure the vent and fuel lines are not kinked.
Do not interchange the supply and return lines (return line is blue or has a blue marking, supply line is black).
Make sure the line connections are securely fastened.
Check both ground connections on the filler tube.
If the fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump.