Fuel Tank, Sedan: Notes

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.

Special tools and workshop equipment required

Torque Wrench 1331 5-50 Nm VAG 1331
Trim Removal Wedge 3409
Engine and Gearbox Jack VAG 1383 A or VAS 6931
Torque Wrench 1332 40-200 Nm VAG 1332

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

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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 bench seat. Refer to REMOVAL AND INSTALLATION .

-- Unclip the locking flange 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 fuel filler door unit -2-. Refer to REMOVAL AND INSTALLATION .

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

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

-- 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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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- 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 REMOVAL AND INSTALLATION .

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 VAG 1383A

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

Fig 8: Identifying Mounting Strap And Bolts

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NOTE: A second technician will be needed for the following procedure.

-- 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.