Removing and installing fuel tank with attached components — VW

🧭 Before you start

Fits: VW Touareg II (7P, 2010–2018)

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• Release connection by pressing button on line coupling.
• Before bolting on fuel tank, check that supply and breather lines are still clipped onto fuel tank.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ Observe the following for all removal and installation work on fuel tank:Route all the various lines, e.g. for fuel, activated charcoal filter system and vacuum and electrical wiring in their original positions.Ensure earth cable is correctly installed and tight between fuel filler neck and body to prevent build-up of an electrostatic charge.Ensure that there is sufficient clearance to all moving or hot components. — Note safety precautions before starting installation work .
2. Observe rules for cleanliness .
3. Remove rear axle Body assembly work, exterior55Repairing rear axle.
4. Open fuel filler flap and unscrew cap.
5. Remove tank flap Body assembly work, exterior55.

6. Pull rubber seal of fuel filler neck downwards.
7. Undo fastening bolts (1) of filler neck and pull off earth wire (2).
8. Remove rear seat bench General body repairs, interior72Removing and installing seat bench.
9. Fold right-hand carpet cut-out to the side.
10. Remove securing nuts (1...4) of flange cover.
11. Remove flange cover.
12. Detach breather line (1). [Note: Release connection by pressing button on line coupling.]
13. ⚠ The fuel supply line is under pressure.Risk of eye and skin injury from fuel.Wear eye protection and protective clothing to avoid eye injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully opening the connection point. — Hold a cleaning cloth on connection of fuel supply line (2) and pull off hose coupling. [Note: Release connection by pressing button on line coupling.]
14. Disconnect connector (3) from fuel gauge sender and connector (4) for fuel pump.
15. Fold left-hand carpet cut-out to the side.
16. Remove securing nuts (1...4) of flange cover.
17. Remove flange cover.
18. Pull connector (arrow) off sender flange.
19. Remove rear right wheel housing liner General body repairs, exterior66Removing and installing wheel housing liner.
20. Unscrew stone guard (arrows).
21. Unclip fuel tank breather lines attached to longitudinal member.
22. Remove securing bolt for filler neck (arrow) in wheel housing.
23. Pull off breather pipes on activated charcoal filter .
24. Now remove securing straps together with covers on right and left under fuel tank.
25. Use engine and gearbox jackV.A.G 1383 A to support fuel tank and then remove securing strap in middle of fuel tank.
26. Carefully lower fuel tank slightly.
27. Disconnect connector from fuel pump control unit J538.
28. Detach breather pipe on pipe coupling . [Note: Release connection by pressing button on line coupling.]
29. Lower fuel tank. [Note: Before bolting on fuel tank, check that supply and breather lines are still clipped onto fuel tank.]

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