Fuel Tank

Special tools and workshop equipment required

Removing

NOTE:

Hose connections are secured with either spring-type or clamp-type clips.

Always replace clamp-type clips with spring-type clips.

Pliers for spring clamps VAS 5024A or hose clamp pliers V.A.G 1921 are recommended for installing spring clamps.

NOTE:

Empty the fuel tank if necessary using the fuel extracting device VAS 5190 FUEL TANK DRAINING .

Read safety precautions before beginning work FUEL SUPPLY SYSTEM SAFETY PRECAUTIONS .

Observe the rules for cleanliness CLEAN WORKING CONDITIONS .

When lowering, the fuel tank must be carefully guided to prevent damages.

-- Turn the ignition and all electrical consumers off and remove the ignition key.

-- Unscrew mounting bolt for fuel flap unit and remove fuel flap unit Removal and Installation .

-- Unclip cover -1- from fuel delivery unit. Arrow -2- points in direction of travel.

Fig 1: Identifying Fuel Delivery Unit Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -1-.

Fig 2: Identifying 4-Pin Connector, Black Supply Line And Blue Return Line From Fuel Delivery Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- On vehicles equipped with an auxiliary heater, the metering pump -V54-.

-- Remove right rear wheel.

-- Remove rear right wheel housing liner Removal and Installation .

-- Unfasten the bolts -1- for fuel filler tube.

Fig 3: Identifying Bolts -1- For Fuel Filler Tube

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the electrical wiring -2- for the ABS speed sensor to the fuel filler tube bracket.

-- Remove the front muffler; it may be necessary to separate the front and rear mufflers beforehand FRONT AND REAR MUFFLERS, SEPARATING AND CONNECTING .

WARNING:

The fuel or fuel lines in fuel system can become very hot (danger of scalding)!
In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!
Wear protective goggles and protective gloves when working on the fuel system!

-- Separate the black supply line and the right front blue return line -arrows- on the fuel tank.

Fig 4: Identifying Supply And Return Lines

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NOTE:

Press in securing ring to disengage the lines.

A second mechanic is required for the remainder of the procedure to help support the fuel tank.

-- Unscrew tension strap mounting bolts -arrows-.

Fig 5: Identifying Fuel Tank Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Slowly lower fuel tank.

-- Unscrew fuel tank at sides.

Installing

Installation is performed in reverse order. When doing this note the following:

Route fuel lines kink-free.
Do not interchange supply and return line (return line blue, supply line black).
Make sure lines connections are securely fastened.
Check ground (GND) connection of fuel tank/chassis at filler tube.
After installing fuel tank, check to be sure lines are still clipped in at fuel tank.