Fuel Tank, Removing And Installing, AWD Vehicles: Removing

WARNING: This page is about a different car, the 2023 Volkswagen Arteon. However, it is still accessible from the selected car via links, so may be relevant.

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

-- Move the front seats all the way forward.

-- Switch off the ignition.

-- Remove the right and left installation opening cover. Refer to INSTALLATION OPENING COVER, REMOVING AND INSTALLING .

-- Unlock and disconnect the connector -1- and -2- from the sealing flange.

Fig 1: Top View Of Fuel Pump

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Vehicles with Parking Heater

-- Release the connector -3- for the Metering Pump -V54- and remove it.

Continuation for all vehicles

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-- Unlock and disconnect the connectors -2- from the sealing flange.

-- Unlock and disconnect the connectors -1- from the sealing flange.

-- If equipped, release and disconnect the connector -3- on the sealing flange.

-- Unclip the connectors from the sealing flange mounts.

-- Remove the Fuel Pump Control Module -J538- with the connected wiring harness. Refer to Fuel Pump Control Module -J538-, REMOVING AND INSTALLING .

-- Remove the Fuel Pump Control Module -J538- between the fuel tank and the floor panel inward.

-- Move the Fuel Pump Control Module -J538- together with the wiring harness to the side.

-- Remove the right rear wheel. Refer to WHEEL, CHANGING .

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

-- Open the fuel filler door unit -2-.

Fig 2: Identifying Fuel Filler Door Unit And Cover

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-- Clean the area around the fuel filler neck.

-- Remove the cap -1- for the fuel filler neck.

-- Seal the fuel filler neck opening with a clean plug to prevent any dirt from getting in.

-- Remove the fuel filler door unit -2-. Refer to FUEL FILLER DOOR UNIT, REMOVING AND INSTALLING .

Tiguan:

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-- Guide out the sealing grommet -1- on the filler tubes -arrows-.

-- Pull out and remove the sealing grommet -1- from the body -2-.

Continuation for All Vehicles:

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-- Remove the fuel filler neck bolts -1- and -2-.

-- Remove the exhaust system rear section. Refer to OVERVIEW - MUFFLER, PASSAT, ARTEON .

-- If equipped, disconnect the left and right rear underbody trim panel in front of the rear axle. Refer to UNDERBODY TRIM PANELS, REMOVING AND INSTALLING .

-- If necessary, loosen the left and right rear center underbody trim panel and lower. Refer to Underbody Trim Panel .

-- Remove and unclip the breather line from the EVAP canister. Refer to OVERVIEW - EVAP SYSTEM . Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Unclip the breather lines -1- and -2- at the bracket -arrows-.

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-- Remove the fuel line -1- from the underbody. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Disconnect the fuel return line -2-. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Vehicles with Parking Heater:

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-- Remove the fuel line -1- from the parking heater. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Continuation for All Vehicles:

-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

-- Unclip the wiring harness -2- for the All Wheel Drive Control Module -J492- on the fuel tank -1-.

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-- Release and disconnect the connector -1- for the AWD clutch.

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-- Unclip the wiring harness on the fuel tank and on the heat shield.

-- Mark the installation position between the wheel bearing housing -1- and the trailing arm -2-.

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-- Use a suitable pen for this.

-- Apply the mark in the area shown -arrow- on the trailing arm.

-- Unclip the wiring harness -1- from the trailing arm -2- -arrows-.

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-- Remove the bolts -3- and pivot the trailing arm -2- downward.

-- Remove the right rear brake caliper. Refer to BRAKE CALIPER, REMOVING AND INSTALLING .

-- Do not open the brake line while doing this.

-- Secure the brake caliper to the body.

-- If equipped, remove the spoiler -1- and -13-. To do so remove the nuts -2- and -14-.

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-- If equipped, remove the underbody trim panels -6- and -11-. Refer to UNDERBODY TRIM PANELS, REMOVING AND INSTALLING .

-- Place the Engine and Gearbox Jack:VAS 6931 -2- under the fuel tank -1- to support it as shown.

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-- Remove the bolts -arrows-.

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NOTE:

The quantity of the bolts is different depending on the vehicle model.

For clarity, the fuel tank is shown without the Engine and Gearbox Jack:VAS 6931 .

A second technician is required to remove the fuel tank.

-- A second technician must support the rear edge of the fuel tank by hand.

-- Lower the fuel tank using the Engine and Gearbox Jack:VAS 6931 .

-- By turning it accordingly, lower the fuel tank sideways.

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

-- A second mechanic is required to guide out the fuel filler neck by hand at the trailing arm.