Volkswagen Cars 2000-05

Fuel Tank

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NOTE
Follow all safety precautions while performing this repair.


CAUTION
Obtain the radio anti-theft code from the customer before disconnecting the battery ground cable.

  1. Ensure the ignition key is OFF , and then disconnect the battery ground cable.
  2.  
  3. Remove the right rear wheel housing.
  4.  
  5. Drain the fuel tank after cleaning the fuel filler neck and surrounding area.
  6.  
  7. Remove the mounting bolts and tank flap unit with splash shield.
  8.  
  9. Remove the mounting bolts on filler neck.
  10.  
  11. Support the tank, using a suitable jack. Take care not to damage the tank.
  12.  
  13. Remove the mounting straps.
  14.  
  15. Lower the jack enough to allow supply/return line and fuel gauge sensor connector to be disconnected.
  16.  
  17. Unclip the supply and return lines from the fuel tank.
  18.  
  19. Lower the fuel tank
  20.  

To install:

Install in the reverse order and note the following:

  1. Route the breather hose to prevent kinks.
  2.  
  3. Ensure the fuel hoses are installed kink free.
  4.  
  5. Secure the hoses with screw clamps.
  6.  


NOTE
Do NOT interchange the supply and return hoses (return hose has blue-on-blue markings, the supply line is black).

  1. Securely clamp the supply and return hoses to the tank.
  2.  

 
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