Fuel tank, removing and installing: Removing

WARNING: This page is about a different car, the 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, 2004 Volkswagen Jetta, and 2004 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

Observe safety precautions. Refer to Safety precautions when working on fuel supply system .

Observe rules for cleanliness. Refer to Rules for cleanliness .

Check whether a coded radio is installed. If so, obtain anti-theft coding.
Open fuel flap.
With ignition switched off disconnect battery ground strap.
Remove rear axle: Refer to 42 REAR SUSPENSION .

Remove right rear wheelhousing liner: Refer to 66 EXTERIOR EQUIPMENT .

Fig 1: Identifying Fuel Tank Securing Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove fuel tank cover.
Drain fuel tank and clean fuel filler neck and surrounding area.
Unscrew securing bolt and remove tank flap unit with rubber cup.
Remove securing bolts on filler neck.
Fold rear seat bench forward.
Remove cover plate from fuel gauge sender and disconnect connector from flange.

Fig 2: Identifying Supply And Return Lines

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect supply and return lines on right front of fuel tank.

CAUTION:

The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
The fuel system is also under pressure! Before opening the system, place cloths around the connection. Then carefully loosen the connection to release the pressure.
Wear eye and hand protection when performing any type of repair work on the fuel system!

NOTE:

Press buttons on hose couplings - arrows - to disconnect fuel line connections.

Remove tensioning strap. When doing this support fuel tank with engine/transmission jack V.A.G 1383 A.
Lower fuel tank.