Fuel Tank, Through 06.07

Fuel System Components

Fuel Tank, through 06.07

• Vehicles through 06.07 have a two piece driveshaft. With these vehicles, the rear subframe only needs to be lowered to remove the fuel tank. Vehicles from 07.07 have a one piece driveshaft. The rear subframe must be completely removed on these vehicles.

• Fuel tank, removing and installing, from 07.07. Refer to => [ Fuel Tank, from 07.07 ]. Fuel Tank, From 07.07

Special tools, testers and auxiliary items required

• Torque Wrench (5 to 50 Nm) (V.A.G 1331)

• Engine/Transmission Jack (V.A.G 1383 A)

Removing

• The rear subframe must be lowered to remove fuel tank.

• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

• Fuel tank and components overview. Refer to => [ Fuel Tank and Components Overview ] Fuel Tank and Components Overview.

- Drain the fuel tank as necessary using (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

- Remove he rear seat bench.

- Remove the cover - 1 - with fuel pump control module (J538) - 2 - from the fuel delivery unit.





- Disconnect the 5 pin connector - arrow - from the flange.





- Disconnect the connector from the all wheel drive control module (J492) - arrow -.





- Remove the grommet - 1 - from the cover and guide the all wheel drive control module wiring harness downward and out.

- Remove the cover - 1 - and disconnect the 3 pin connector - arrow - from the flange.





- Remove the right rear wheel.

- Remove the right rear wheel housing liner.





- Disconnect the vent lines and vacuum line - arrows - from the Evaporative Emission (EVAP) canister.





- Unclip the electrical wire - arrows - from the fuel filler tube.

- Remove the fuel filler door unit.

- Remove the fuel filler tube to body bolts - arrows -.





- Remove the left and right underbody trim from the underbody.

- Remove the tunnel bridge bolts - arrows - and bridge from the underbody.





- Remove the center muffler together with both rear mufflers. Refer to => [ Front Exhaust Pipes with Catalytic Converters and Front Mufflers ] Front Exhaust Pipes With Catalytic Converters and Front Mufflers.

- Remove the heat shield under the driveshaft.

- Remove the driveshaft.

- Remove the heat shield under the fuel tank.

CAUTION!
The fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then carefully disconnect the connection to release the pressure.

- Disconnect the ventilation line, fuel line and vacuum line - A, B and C - at the connection point.





• Press in the securing ring to disengage the fuel line.

- Unclip the brake lines - arrow - of the left of the body.





- Support the rear subframe using (V.A.G 1383 A).

- Loosen the bolts - arrows - and lower the rear subframe.





- Remove the securing strap/fuel tank bolts - arrows -. Support the fuel tank using (V.A.G 1383 A) beforehand.





- Slowly the lower fuel tank and unclip the wire from the all wheel drive control module at fuel tank.

• Fuel filler tube must be removed between the chassis and rear subframe. To do so, lift the fuel tank with help from a second technician, down from the (V.A.G 1383 A).

Installing

- With help from a second technician, guide the fuel filler neck between the rear subframe and chassis. Then place fuel tank onto (V.A.G 1383 A).

- Clip the wire for the all wheel drive control module to the fuel tank - arrows -.





- Lift the fuel tank slowly up to the installed position and install the securing strap/fuel tank bolts - arrows -.





• To secure the fuel tank straps, only bolts with loose washers may be used. If other bolts are used, the straps could twist when the bolts are tightened.

- Install the rear subframe to the chassis.

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

- Note the location of the covers - arrows -:





- Arrows - on the covers must point in the direction of travel.

A Fuel delivery unit cover
B Fuel level sensor 2 cover

• Make sure the vent and fuel lines are not kinked.

• Pull on the line connections to make sure they are securely connected.

• Check the Ground (GND) connection for the fuel tank/chassis at the filler tube.

• If the fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump, refer to "Guided Functions" in the vehicle diagnostic tester.

Tightening Specifications