Fuel Tank, Sedan

Special tools and workshop equipment required 

• Torque Wrench 1331 5-50NmVAG1331
• Trim Removal Wedge3409
• Engine and Gearbox JackVAG1383 A or VAS6931
• Torque Wrench 1332 40-200NmVAG1332

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

-- 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 .

-- Turn off the ignition and all electric consumers and remove the key.

-- Open the fuel filler door.

Fig 1: Filler Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 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- from the fuel delivery unit.

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. .

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

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

Fig 4: Black Supply Line And White Bleed Line

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

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

Fig 5: Identifying Bolts

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-- Remove the ABS line -arrows- from the retainers.

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

Fig 6: Identifying ABS Line

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-- Place the Engine and Gearbox Jack VAG 1383A or VAS 6931 under the fuel tank for support.

Fig 7: Identifying Engine/Gearbox Jack VAG1383A

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-- Remove the mounting strap and bolts -arrows-.

Fig 8: Identifying Mounting Strap And Bolts

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-- Move the fuel tank downward once it is removed from the rear axle. While doing this turn the fuel tank to the left.

-- Remove the fuel tank downward. While doing this turn the fuel tank slightly to the left. The filler tube can then be guided past the rear axle.

Installing 

Installation takes in reverse order of removal. Note the following:

-- Guide the filler neck between the rear axle and the body.

-- Position the fuel tank together with the mounting straps on the underbody using the Engine and Gearbox Jack VAG 1383A or VAS 6931.

-- If equipped, make sure the Metering Pump -V54- is seated securely on the bracket.

-- Be careful to guide the fuel tank filler tube correctly into the opening in the body.

-- Make sure vent and fuel lines are not kinked.

-- Make sure the supply, return and breather lines are still clipped to the fuel tank after the fuel tank has been installed.

-- Make sure the exhaust system bracket is seated correctly. Refer to REAR MUFFLER .

-- Note the location of the tensioning strap.

-- Make sure the line connections are securely fastened.

-- Check the fit by pulling on it.

-- Check the ground wires for traces of oxidation on the connectors. Remove any oxidation if necessary.

Fig 9: Identifying Spacer Bushing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Check the installation position of the ground connection.

• The connector -2- must be securely attached to the metal ring -3-.
• Engage the contact -1- in the fuel tank -4- and secure it with the spacer -5-.

-- Check the connection between the metal ring on the fuel filler neck to an empty area on the body with a ohmmeter.

• Specified value is approximately 0 ohm.
• If the specified values is incorrect, then is a risk of explosion due to discharge of static electricity.

-- Fill at least five liters of fuel in the fuel tank.

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

Tightening Specifications 

• OVERVIEW - FUEL TANK, CONVERTIBLE 
• Refer to FASTENER TIGHTENING SPECIFICATIONS .
• Refer to FASTENER TIGHTENING SPECIFICATIONS .
• Refer to FASTENER TIGHTENING SPECIFICATIONS .
• Refer to WHEEL BOLT TIGHTENING SPECIFICATIONS .