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Home >> Volkswagen >> 2010 >> Jetta Sedan (1K2) L4-2.0L DSL Turbo (CJAA) >> Repair and Diagnosis >> Powertrain Management >> Fuel Delivery and Air Induction >> Fuel Tank >> Service and Repair >> Removal and Replacement >> Fuel Tank

Fuel Tank






Fuel Tank

Special tools, testers and auxiliary items required

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

• Engine/Transmission Jack (V.A.G 1383 A)


• Observe the safety precautions when working on the fuel supply system. Refer to => [ Safety Precautions ] Fuel Supply.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.

Always follow these instructions before and during work.

Conditions

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

Removing

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


Electronic components could be destroyed when the batter is disconnected:

• Follow the required steps when disconnecting the battery.

- Turn off the ignition and disconnect the ground cable - arrow - from the battery.






- Clean the surrounding area around the fuel filler tube.

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

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

- Remove the right rear wheel housing liner.

- Remove the fuel filler neck bolts - 1 -.






- Disengage the wire - 2 - for the Anti-lock Brake System (ABS) speed sensor from the filler tube bracket.

- Remove the rear seat bench.

- Unclip the cover - 1 - for the fuel delivery unit. Arrow - 2 - points in direction of travel.






- Disconnect the connector - 1 - from the fuel delivery unit flange.






- Remove the center muffler or the exhaust pipe. Refer to one of the following:

• Engine Code CBEA, refer to => [ Muffler Overview ] Service and Repair.

• Engine Code CJAA, refer to => [ Muffler Overview ] Service and Repair.

• The front and rear mufflers may have to be separated first, refer to => [ Exhaust System, Separating and Connecting ] Exhaust System, Separating and Connecting.


• Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before loosening line connections, place cloths around the connection point. Then release pressure by carefully disconnecting the line.

- Disconnect the black supply line - 1 - and the blue return line - 2 - between the fuel tank and body.






• Press in the securing rings to disengage the fuel lines.

- Seal the lines so that the fuel system is not contaminated by dirt, etc.

• A second technician is required for the remainder of the procedure to help support the fuel tank.

- Remove the securing strap bolts - arrows -. Support the fuel tank using the engine/transmission jack (V.A.G 1383 A) while doing so






- Slowly lower the fuel tank.

• The fuel filler neck must be "guided out" between the body and rear subframe. To do so, lift the fuel tank down from the engine and transmission jack (V.A.G 1383 A) with the help of a second technician.

Installing

- With the help of a second technician, guide the fuel filler neck in between the rear subframe and body. Then place the fuel tank onto the engine and transmission jack (V.A.G 1383 A).






- Lift the fuel tank slowly up to the installed position and secure it with new bolts - arrows -. Tightening specification, refer to one of the following:

• Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10: see - item 7 - in => [ Fuel Tank Overview ] Fuel Tank Overview.

Further installation is performed in reverse order. When doing this note the following:

- Tightening specifications, refer to one of the following:

Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10:=> [ Fuel Tank Overview ] Fuel Tank Overview.

• Route the fuel lines free of kinks.

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

• Make sure the line connections are seated securely.

• Check the fuel tank/body ground connection on the filler neck to make sure it is seated securely, refer to one of the following:

• Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10: see - item 3 - in => [ Fuel Tank Overview ] Fuel Tank Overview

• After checking the installation of the fuel tank, make sure the fuel lines are still clipped onto the tank.

- Observe the notes after connecting the battery.
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