Fuel Tank

WARNING: This page is about a different car, the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Torque Wrench (5-50 Nm) V.A.G 1331

Removing

The fuel tank may be a maximum of 1/4 full.

NOTE:

Drain the fuel tank if necessary, using the fuel extracting device VAS 5190. Refer to FUEL TANK, DRAINING .

Read the safety precautions before starting. Refer to SAFETY PRECAUTIONS .

Pay attention to the rules of cleanliness. Refer to CLEAN WORKING CONDITIONS .

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

-- Open the fuel filler flap and remove the fuel filler cap.

-- Remove the bolt from the fuel filler door unit and then remove the fuel filler door unit. Refer to Removal and Installation .

-- Remove the rear bench seat. Refer to Removal and Installation .

-- Remove the cover -2- and fuel pump control module -J538- -2- from the fuel delivery unit.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

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-- Disconnect the connector -arrow-.

Fig 2: Fuel Pump Control Module Connector

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-- Remove the right rear wheel housing liner. Refer to Removal and Installation .

-- Clean the surrounding area around the fuel filler tube.

Jetta/GLI for MY 08 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09:

-- Disconnect the connectors -2 and 4-.

Fig 3: Disconnecting Fuel Filler Tube Connections

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-- Remove the fuel filler tube bolts -arrows-.

GLI from MY 12

-- Remove the ventilation line -1- from the filler tube. To do so, press in the securing ring.

Fig 4: Identifying Ventilation Line

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-- Remove the ventilation line from the bracket -arrow-.

-- Remove the bolts -1-.

Continuation for all Vehicles:

-- Unclip the Anti-lock Brake System (ABS) wire -A- from the bracket -arrows-.

Fig 5: Unclipping ABS Line From Bracket

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-- Remove the front muffler, the front and rear mufflers must be separated beforehand, if necessary. Refer to FRONT AND REAR MUFFLERS, SEPARATING AND CONNECTING .

WARNING:

The fuel system is under pressure!

Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

-- Disconnect the ventilation line from the Evaporative Emission (EVAP) canister connection behind the fuel tank only.

-- Disconnect the white ventilation line -1-, black supply line -2- and the green vacuum line for the leak detection pump -V144- -3- (The green vacuum line is only on the Jetta/GLI for MY 08 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09).

Fig 6: Separating White Vent Line, Black Supply Line And Green Vacuum Line For Leak Detection Pump (LDP) V144 At Connecting Point

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NOTE:

Press in the securing ring to disengage the lines.

For the continuing work sequence, a second mechanic is needed to support the fuel tank.

-- Remove the tensioning strap bolts -arrows- and strap.

Fig 7: Identifying Fuel Tank Bolts

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-- Remove the fuel tank side bolts -arrows-.

Installing

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

Only use bolts with loose washers to secure the fuel tank straps. The straps could twist when the bolts are tightened if other bolts are used.
Make sure the vent and fuel lines are not kinked.
Do not interchange the supply and return line (supply line is black, return line is blue).
Make sure the line connections are securely fastened.
Check the fuel tank/body ground connection on the filler tube.
After installing the fuel tank, check to be sure the lines are still clipped onto the fuel tank.

Tightening Specifications

Component		Nm
Fuel tank to chassis - M6		11
Fuel tank to chassis - M8 Replace the bolts		26