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 -.
Open fuel filler cap 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 cover for locking flange - arrows - in luggage compartment.

Fig 5: Identifying Locking Flange Electrical Harness Connectors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - 1 - at locking flange.
Disconnect electrical connector - 2 -.

Vehicles with hose connection:

Fig 6: Disconnecting Ventilation Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect ventilation line - 1 -.

Vehicles with connection coupling:

Fig 7: 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 off - arrow B -.

All models:

Fig 8: Opening Tank Flap And Cleaning Area Around Fuel Filler Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Open tank flap and clean area around fuel filler tube.

NOTE:

Do not remove fuel cap.

Pry tensioning ring - arrow - out from rubber gasket and press rubber gasket through toward inside.

Fig 9: Disconnecting Ventilation Line From Fuel Filler Tube & Removing 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
.
Disconnect ventilation line - 2 - from fuel filler tube.
Remove bolts - 1 - for fuel filler tube.

Fig 10: 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 11: Removing Ventilation Lines

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove 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 at top from bracket - arrow -.

Fig 12: Removing Vehicle Floor Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove vehicle floor cover - arrows -.

Fig 13: 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 14: 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 the areas indicated with - arrows -.

Fuel system with return line:

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 15: Disconnecting Fuel Supply Line From Fuel Filter & Fuel Return Line And Ventilation Line At Connection Point

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect fuel supply line - 1 - from fuel filter, by pressing release buttons. Catch escaping fuel.
Disconnect fuel return line - 3 - and ventilation line - 2 - at connection point, by pressing release buttons.

Fuel system without return line:

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 16: Separating Ventilation Line And Fuel Line From Right Front Of Fuel Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate ventilation line - 2 - and fuel line - 1 - from right front of fuel tank, by pressing release buttons.

All models:

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 17: 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:

NOTE:

Secure all hose connections using hose clamps appropriate for the model type .

Fig 18: 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 19: Identifying Connector Is Securely Attached To Metal Ring & Contact Is Hooked Into Fuel Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The connector - 3 - must be securely attached to metal ring - 2 -.
The contact - 1 - must be hooked into fuel tank - 4 -.

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 20: 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 metal ring at fuel filler tube to a blank portion of chassis using Ohm meter:

Specification: approx. 0 Ohm.

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 bolts 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