Fuel tank, removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including 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 before performing repair work. Refer to Safety precautions when working on fuel supply system .

CAUTION: When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
Ensure sufficient clearance to all moving or hot components.
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!

Check whether a coded radio is installed. If necessary, obtain the anti-theft coding.
Disconnect battery Ground (GND) strap with ignition switched off.
Remove rear axle: Refer to 42 REAR SUSPENSION

Vehicles with all wheel drive (AWD)

Remove rear axle: Refer to 42 REAR SUSPENSION

Continue for all vehicles

Remove right rear wheel housing liner: Refer to 66 EXTERIOR EQUIPMENT

Vehicles with front wheel drive (FWD)

Fig 1: Identifying Fuel Tank Securing Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cover for fuel tank.

Continue for all vehicles

Open fuel tank flap.
Drain fuel tank and clean fuel filler tube and surrounding area.
Remove securing bolts 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.

Vehicles with all wheel drive (AWD)

Remove cover plate from fuel pump flange and disconnect 4-pin connector from flange.

CAUTION:

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!

Continue for all vehicles

Fig 2: Identifying Supply And Return Lines

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect fuel supply line and return line on right front at fuel tank.

NOTE:

Press buttons on hose couplings - arrows - downward to do this.

Vehicles with all wheel drive (AWD)

Fig 3: Identifying Fuel Tank Securing Bolts & Nuts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove securing bolts/nuts - arrows -.

Continue for all vehicles

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