Fuel tank, removing and installing

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Fuel Siphoning Unit VAS 5190

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fuel siphoning unit VAS 5190

Fig 2: Engine/Transmission Jack V.A.G 1383 A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine/transmission jack V.A.G 1383 A
Torque wrench V.A.G 1331

Removing

Observe safety precautions before performing repair work, refer to Safety precautions when working on fuel supply system .

NOTE:

To perform work sequence, the Ground cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti-theft coding beforehand.

With ignition switched off disconnect battery Ground (GND) strap.
Open fuel tank flap.

Fig 3: Fuel Siphoning Unit VAS 5190 Suction Hose In Fuel Filler Neck

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Push suction hose - arrow - of fuel siphoning unit VAS 5190 about 100 to 120 cm into fuel filler neck and extract fuel.
Unscrew securing bolts and remove tank flap unit with rubber cup.
Remove securing bolts on filler neck.
Remove rear right wheel housing liner: Refer to 66 EXTERIOR EQUIPMENT

Clean area surrounding fuel filler tube.
Fold rear seat bench forward.
Remove right and left cover under the bench seat.
Remove heat shield under the fuel tank

Remove rear axle: Refer to 42 REAR SUSPENSION

CAUTION: Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

Fig 4: Identifying Return Line, Supply Line And Breather Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate return line - 2 - (blue), supply line - 1 - (black) and breather line - 3 - (white) at their connection points.

NOTE:

Press buttons on hose couplings to do this.

Fig 5: Fuel Tank Bolts/Nuts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove securing bolts/nuts - arrows -.
Remove tensioning strap. Support fuel tank using engine/transmission jack V.A.G 1383 A while doing so
Lower fuel tank.

Installing

Installation is performed in reverse order of removal. Note the following:

Make sure ventilation and fuel lines are not kinked when installed.
Secure fuel hoses with spring-type clamps.
Route fuel hoses kink-free.
Ensure fuel hoses are seated securely.

Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).

NOTE:

After installing fuel tank, check that the supply, return and breather lines are still clipped onto the fuel tank.