Fuel tank, removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, 2003 Volkswagen Jetta, and 2003 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

Observe safety precautions before starting work → Safety precautions when working on the fuel supply system .
Check whether a coded radio is installed. If so, obtain anti-theft coding.
With ignition switched off disconnect battery Ground strap.
Open fuel flap.

Remove rear right wheel housing liner: → 66 EXTERIOR EQUIPMENT
Remove rear axle: → 42 REAR SUSPENSION
Drain fuel tank, clean fuel filler neck and surrounding area.
Unscrew mounting screw and remove tank flap unit with rubber cup.

Remove securing screws on filler neck.
Fold rear seat bench forward.
Remove cover from fuel delivery unit.

Fig 1: Fuel Delivery Connector

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Remove 4-pin connector from flange - arrow -.

Fig 2: Cover & Bolts From Under Fuel Tank

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Remove cover for fuel tank - arrows -.

Fig 3: Fuel Supply Hose, Return Hose & Breather Hose

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect return line - 2 - (blue), supply line - 1 - (black) and breather line - 3 - (white) at connecting point.

NOTE:

Press buttons on hose couplings to do so.

CAUTION: Fuel supply lines are under pressure! Before removing from hose connections wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

Seal lines to avoid contamination of fuel system.
Remove tensioning strap. When doing this support fuel tank with Engine and gearbox jack VAG 1383 A.
Lower fuel tank.