Fuel Tank, Vehicles With Twist Beam Suspension: Removing

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 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.

NOTE:

Observe the safety precautions. Refer to SAFETY PRECAUTIONS .

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

-- Move the front seats all the way forward.

-- Fuel Tank, Draining. Refer to FUEL TANK, DRAINING .

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

-- Open the fuel filler door and the fuel cap.

-- Remove the bench seat. Refer to REMOVAL AND INSTALLATION .

-- Fold the carpet up at the right in the area of the fuel delivery unit.

-- If equipped, remove the cover -1- and Fuel Pump Control Module -J538- -2- from the fuel delivery unit.

Fig 1: Identifying Cover With Fuel Pump Control Module J538

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-- Unclip the cover -1- at the tabs -arrows- using the Trim Removal Wedge 3409.

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 right rear wheel housing liner. Refer to REMOVING .

Vehicles with EVAP Canister Installed in the Right Rear Wheel Housing.

-- Disconnect all lines from the EVAP canister to the filler neck. Refer to CONNECTOR COUPLINGS, SEPARATING .

Continuation for All Vehicles

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

Fig 4: Identifying Bolts

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

-- Disconnect the vent line -1- (white) and supply line -2- (black) at the connecting point. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 5: Disconnecting Vent Line (White) And Supply Line (Black) At Connecting Point

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-- Loosen the clamping sleeve -9-.

Fig 6: Identifying Muffler, Twist Beam Suspension Components Overview

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NOTE:

A second technician is required for the remainder of the procedure to help support the exhaust system.

-- Remove the rear section of the exhaust system from the body and lay it on the twist beam rear suspension.

The exhaust system is then hanging by the rear axle and the rear tunnel brace.

-- Push the exhaust system as far as possible to the left.

-- Remove the mounting strap and bolts -arrows-. Have a second technician hold the fuel tank -1- while doing this.

Fig 7: Identifying Mounting Strap And Bolts

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Always make sure there is enough clearance for the filler tube to prevent damaging the fuel tank while removing it.

-- 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.