Fuel Tank

WARNING: This page is about a different car, the 2009 Volkswagen GTI and 2008 Volkswagen GTI. 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-
Engine-/Gearbox Jack -V.A.G 1383 A-

Removing

-- Read the safety precautions before beginning work. Refer to SAFETY PRECAUTIONS .

-- Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

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

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

-- Remove the cover -1- with the 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: Identifying Fuel Pump Control Module Connector

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-- Remove the right rear wheel.

-- Remove right rear wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

-- Remove the bolt for the fuel flap unit and remove the fuel flap unit. Refer to Removal and Installation .

Fig 3: Identifying Hoses -1 And 2-

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-- Disconnect the hoses -1 and 2-.

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

-- Unclip the electrical wire from the filler connection.

-- Remove the center and rear mufflers.

-- Remove the heat shield from the center and rear mufflers.

WARNING:

The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

NOTE:

Press in the securing rings to disengage the fuel lines.

-- Disconnect the vent line -1- (white) and the fuel line -2- (black) at the connecting point.

Fig 4: Identifying Vent Line (White) And Supply Line (Black)

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NOTE:

The green leak detection pump -V144- vacuum line must also be disconnected.

-- Remove the strap bolts and straps. Support the fuel tank using the engine-/gearbox jack -V.A.G 1383 A- while doing so

Fig 5: Identifying Fuel Tank Bolts

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-- Lower the fuel tank.

Installing

Install in reverse order of removal. When doing this note the following:

Tightening specifications, refer to FUEL TANK AND ATTACHMENTS OVERVIEW .

To secure the fuel tank straps, only bolts with loose washers may be used. If other bolts are used, the straps could twist when the bolts are tightened.
Make sure the vent and fuel lines are not kinked.
Do not interchange the supply and return lines (the return line is blue or has blue marks, the supply line is black).
Pull on the line connections to make sure they are securely fastened.
Check the fuel tank/body ground connection on the filler tube.