Fuel Tank

Fuel Tank

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

Removing

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

• Drain the fuel tank if necessary, using the fuel extracting device (VAS 5190). Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.

• Read the safety precautions before starting. Refer to => [ Safety Precautions ] Fuel Supply.

• Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

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

- Open the fuel filler flap and remove the fuel filler cap.

- Remove the bolt from the fuel filler door unit and then remove the fuel filler door unit.

- Remove the rear bench seat.

- Remove the cover - 2 - and fuel pump control module (J538) - 2 - from the fuel delivery unit.






- Disconnect the connector - arrow -.






- Remove the right rear wheel housing liner.

- Clean the surrounding area around the fuel filler tube.

Jetta/GLI for MY 08 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09:

- Disconnect the connectors - 2 and 4 -.






- Remove the fuel filler tube bolts - arrows -.

GLI from MY 12

- Remove the ventilation line - 1 - from the filler tube. To do so, press in the securing ring.






- Remove the ventilation line from the bracket - arrow -.

- Remove the bolts - 1 -.

Continuation for all Vehicles:

- Unclip the Anti-lock Brake System (ABS) wire - A - from the bracket - arrows -.






- Remove the front muffler, the front and rear mufflers must be separated beforehand, if necessary. Refer to => [ Front and Rear Mufflers, Separating and Connecting ] Service and Repair.


The fuel system is under pressure!

• Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.

• Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

- Disconnect the ventilation line from the Evaporative Emission (EVAP) canister connection behind the fuel tank only.

- Disconnect the white ventilation line - 1 -, black supply line - 2 - and the green vacuum line for the leak detection pump (V144) - 3 - (The green vacuum line is only on the Jetta/GLI for MY 08 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09).






• Press in the securing ring to disengage the lines.

• For the continuing work sequence, a second mechanic is needed to support the fuel tank.

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






- Remove the fuel tank side bolts - arrows -.

Installing

Installation is performed in the reverse order of removal. When doing this note the following:

• Only use bolts with loose washers to secure the fuel tank straps. The straps could twist when the bolts are tightened if other bolts are used.

• Make sure the vent and fuel lines are not kinked.

• Do not interchange the supply and return line (supply line is black, return line is blue).

• Make sure the line connections are securely fastened.

• Check the fuel tank/body ground connection on the filler tube.

• After installing the fuel tank, check to be sure the lines are still clipped onto the fuel tank.

Tightening Specifications