Fuel Tank

WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. 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 .

-- If necessary, take out the adapter for the wheel rim lock from the luggage compartment.

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

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

-- Remove the rear seat bench. Refer to "Rear Seats" in Removal and Installation .

-- Remove the cover -1- for the fuel delivery unit. The arrow -2- points in the direction of travel.

Fig 1: Identifying Cover Of Fuel Delivery Unit & Direction Of Travel

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-- Disconnect the connector -1- and the lines -2 and 3- from the fuel delivery unit. Disconnect the couplings, refer to COUPLING, DISCONNECTING .

Fig 2: Disconnecting 5-Pin Connector, Black Supply Line And Blue Return Line

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

-- Disconnect the lines -1 and 2-.

Fig 3: Disconnecting Hoses

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

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

Fig 4: Unclipping ABS Line From Bracket

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-- Remove the exhaust system.

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. Before loosening the fuel lines, place a cloth around the connection point. Remove the hose connection carefully to release the pressure.

-- Disconnect the white vent line -1-, the black supply line -2- and the green vacuum line for the leak detection pump -V144- -3- at the separating point. Disconnecting the couplings, refer to COUPLING, DISCONNECTING .

Fig 5: Disconnecting White Vent Line, Black Supply Line And Green Vacuum Line For Leak Detection Pump (LDP) V144

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NOTE:

A second technician is required for the rest of this procedure to help support the fuel tank.

-- Remove the securing straps and bolts -arrows-.

Fig 6: Identifying Fuel Tank Bolts

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

Installing

Install in reverse order of removal. Note the following:

Make sure the vent and fuel lines are not kinked.
Do not confuse the supply line and the return line (the supply line is black and the return line is blue).
Make sure lines connections are securely fastened.
Check the fuel tank/body ground connection on the filler tube.
Make sure the lines are still attached to the fuel tank after installing the fuel tank.

-- Bleed the fuel system. Refer to FUEL SYSTEM, FILLING AND BLEEDING .

-- Connect the battery. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] Removal and Installation

Tightening Specifications

Component		Nm
Fuel tank to chassis - M6		10
Fuel tank to chassis - M8 Replace the bolts.		25