Fuel tank with attachments, removing and installing

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, the 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 -.
All:
Open fuel filler flap briefly and then close again.

Sedan:

Remove carpeting in luggage compartment.
Fold forward 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 locking flange cover in luggage compartment - arrows -.

Fig 5: Disconnecting Electrical Harness Connector At Locking Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - at locking flange.

Fig 6: Disconnecting Ventilation Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect ventilation line - 1 -. Do this by pressing releasing ring - 2 - approx. 2 mm in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
Open tank flap and clean 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 inside.

Fig 8: Removing Ventilation Line From Fuel Filler Tube & Bolts For Fuel Filler Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove right rear wheel.
Remove right rear wheel housing liner →
- 66 EXTERIOR EQUIPMENT
- 66 - EXTERIOR EQUIPMENT for BODY EXTERIOR - CABRIOLET
.
Pull ventilation line - 2 - off 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.

Disconnect ventilation lines - 1 - and - 2 -. Do this by pressing releasing ring - 3 - in direction of - arrow A - and simultaneously pulling ventilation line - arrow B - off.
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 Of Fuel Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate ventilation line - 1 - and fuel line - 2 - from right 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 to 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 the metal ring at fuel filler tube to a blank portion of chassis using Ohm meter:

Specification: approx. 0 Ω.

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, by fastening screws 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