Fuel Tank

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. 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) VAG 1331
Engine and transmission jack VAG 1383A

Removing

Fuel tank may be a maximum of 1/4 full.

NOTE:

Empty the fuel tank if necessary using the VAS 5190. Refer to FUEL TANK, DRAINING .

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

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

-- Switch off the ignition, switch off all electrical components and remove the ignition key.

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

-- Remove the fuel filler door unit. Refer to Removal and Installation .

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

-- Remove the cover -1- with the fuel pump control module -2-.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

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-- Disconnect the electrical connector -1- from the fuel delivery unit.

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

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

-- Disconnect the connections -1 and 2-.

Fig 3: Identifying Fuel Filler Tube Connections

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

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

Fig 4: Identifying ABS Line At 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 supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting, wrap a cloth around the connection point. Then release the pressure by carefully disconnecting the connection.

-- Disconnect the white vent line -1-, black supply line -2- and green vacuum line for Leak Detection Pump (LDP) -3- at the connecting points.

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

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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 mounting strap bolts -arrows-. Support the fuel tank using the VAG 1383A while doing so

Fig 6: Identifying Fuel Tank Bolts

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-- Remove the fuel tank bolts at the sides and remove the fuel tank.

Installing

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

Make sure vent and fuel lines are not kinked.
Do not interchange the supply and return line (return line blue, supply line black).
Make sure the line connections are securely fastened.
Check the ground connection of fuel tank/chassis at filler tube.
After installing the fuel tank, check to be sure lines are still clipped onto the at fuel tank.
If the fuel delivery unit was replaced, adapt the Engine Control Module (ECM) to the fuel pump. Refer to vehicle diagnosis, testing and information system VAS 5051 or vehicle diagnosis and service systemVAS 5052.

Tightening Specifications

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