Fuel Tank, Convertible: Removing

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

-- Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to PARKING/AUXILIARY HEATER AND FUEL SYSTEM CLEAN WORKING CONDITIONS .

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

-- Open the fuel filler door.

Fig 1: Filler Cap

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-- Clean the area around the fuel filler tube.

-- Remove the locking cap -arrow- from the fuel filler tube.

-- Drain the fuel tank. Refer to FUEL TANK, DRAINING .

-- Remove the rear bench seat. Refer to REAR SEATS .

-- Unclip the locking flange cover -1- at the tabs -arrows- using the Trim Removal Wedge3409.

Fig 2: Identifying Right Cover

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-- Disconnect the connector -arrow-.

Fig 3: Fuel Pump Control Module Connector

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-- Remove the fuel filler door unit -2-. Refer to FUEL FILLER DOOR UNIT .

-- Remove the right rear wheel. Refer to REMOVAL AND INSTALLATION .

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

-- Remove the seal -1- from the filler neck -2- and from the body -3-.

Fig 4: Identifying Seal And Filler Neck

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-- Remove the bolts -1- and -2- from the filler tube.

Fig 5: Identifying Bolts

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-- Unclip the wire at the filler neck -2-.

-- Remove the rear section of the exhaust system. Refer to REAR MUFFLER .

Fig 6: Identifying ABS Line

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-- Remove the fuel lines -1- and -2- from the underbody. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 7: Identifying Ventilation Line (White) -1- And Fuel Line (Black) -2-

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WARNING:

Fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose connections. Open the connection carefully and release the pressure.

-- If the vehicle has an auxiliary heater, disconnect the connector from the metering pump and unclip the cable. .

-- Remove the bolts -1- through -4- and then remove the tension struts -A- and -B-. Refer to TENSION STRUTS OVERVIEW .

Fig 8: Identifying Bolts

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-- Remove the bolts -1- and -3-.

Fig 9: Fuel Tank Support Bracket Screws

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-- Place the Engine and Gearbox JackVAG1383A or VAS6931 under the fuel tank for support.

Fig 10: Identifying Engine/Gearbox Jack VAG1383A

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-- Remove the bolts -2- and -4-.

Fig 11: Fuel Tank Support Bracket Screws

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NOTE:

A second technician is required to remove the fuel tank.

-- Lower the fuel tank and remove it from the body.