Fuel Tank

WARNING: This page is about a different car, the 2010 Volkswagen Jetta and 2009 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) V.A.G 1331
Engine-/Gearbox Jack V.A.G 1383 A

CAUTION:

Observe the safety precautions when working on the fuel supply system. Refer to SAFETY PRECAUTIONS .
Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Always follow these instructions before and during work.

Conditions

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

Removing

NOTE:

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

CAUTION:

Electronic components could be destroyed when the battery is disconnected:

Follow the required steps when disconnecting the battery.

-- Turn off the ignition and disconnect the ground cable -arrow- from the battery. Refer to Removal and Installation .

Fig 1: Identifying Battery And Ground Cable

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Open the fuel tank flap and remove the fuel tank 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 right rear wheel housing liner. Refer to Removal and Installation .

-- Remove the fuel filler neck bolts -1-.

Fig 2: Identifying Fuel Filler Neck Bolts -1- And Wire -2-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disengage the wire -2- for the Anti-lock Brake System (ABS) speed sensor from the filler tube bracket.

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

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

Fig 3: Identifying Fuel Delivery Unit Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the center muffler or the exhaust pipe. Refer to one of the following:

Engine Code CBEA, refer to MUFFLER OVERVIEW .
Engine Code CJAA, refer to MUFFLER OVERVIEW .

NOTE:

The front and rear mufflers may have to be separated first, refer to EXHAUST SYSTEM, SEPARATING AND CONNECTING .

CAUTION:

The fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin.
Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully disconnecting the line.

-- Disconnect the black supply line -1- and the blue return line -2- between the fuel tank and body.

Fig 5: Identifying Black Supply Line -1- And The Blue Return Line -2-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Press in the securing rings to disengage the fuel lines.

-- Seal the lines so that the fuel system is not contaminated by dirt, etc.

NOTE:

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

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

Fig 6: Identifying Fuel Tank Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Slowly lower the fuel tank.

NOTE:

The fuel filler neck must be "guided out" from between the body and rear subframe. To do so, lift the fuel tank down from the engine-/gearbox jack V.A.G 1383 A with the help of a second technician.

Installing

-- With the help of a second technician, guide the fuel filler neck in between the rear subframe and body. Then place the fuel tank onto the engine-/gearbox jack V.A.G 1383 A.

Fig 7: Identifying Fuel Tank Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lift the fuel tank slowly up to its installed position and secure it with new bolts -arrows-. Tightening specification, refer to one of the following:

Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, see -item 7- in the FUEL TANK OVERVIEW .
Jetta from MY 11, see -item 8- in the .

Further installation is performed in reverse order. When doing this note the following:

-- Tightening specifications, refer to one of the following:

Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, refer to FUEL TANK OVERVIEW .

Jetta from MY 11, refer to .

Route the fuel lines free of kinks.
Do not interchange the supply and return lines (the return line is blue, the supply line is black).
Make sure the line connections are seated securely.
Check the fuel tank/body ground connection on the filler neck to make sure it is seated securely, refer to one of the following:
Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, see -item 3- in the FUEL TANK OVERVIEW .
Jetta from MY 11, see -item 3- in the .
After checking the installation of the fuel tank, make sure the fuel lines are still clipped to the tank.

-- Observe the notes after connecting the battery. Refer to Removal and Installation .