Volkswagen Cars 2000-05

Removal & Installation

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Always ground yourself to the vehicle's chassis to prevent sparks while working on or around the fuel tank.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the access panel under the rear seat or in the luggage compartment.
  4.  
  5. Disconnect the gauge sending unit wiring and hoses.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Drain the fuel tank into an approved container.
  10.  
  11. On Cabriolet models, remove the right rear inner fender and disconnect the breather hose from the filler. Remove, but do not disconnect the gravity valve.
  12.  
  13. Detach the fuel pump bracket from the body.
  14.  
  15. Lower the pump enough to disconnect the fuel hoses from the tank.
  16.  
  17. On Cabriolet models, the rear axle must be dropped out of the way as follows:
    1. Disconnect the brake hydraulic hoses at both sides of the rear axle.
    2.  
    3. Detach the rear axle from the body on both sides and let it hang on the parking brake cables.
    4.  

  18.  
  19. Unhook the muffler supports and pull the large hose from the filler neck.
  20.  
  21. Support the tank, loosen the straps and carefully lower the tank out of the vehicle.
  22.  

To install:

  1. If a new tank is being installed, glue new foam strips to the tank in the same location as the old ones.
  2.  
  3. Position the tank and secure it with the straps.
  4.  
  5. Connect the wiring and hoses to the sending unit.
  6.  
  7. Attach the fuel pump bracket to the body.
  8.  
  9. On Cabriolet models, install the rear axle, connect the hydraulic lines and bleed the brakes.
  10.  
  11. Install the access panel once all electrical connections have been made.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Fill the tank with fuel and check for leaks.
  16.  

1.8L Engines




NOTE
This procedure requires the use of V.A.G. 1383 or equivalent Engine and Transaxle jack.


NOTE
The fuel extraction unit VAS 5190 is recommended for emptying the fuel tank.

  1. If the vehicle has a coded radio, make sure you have the anti-theft code before beginning the procedure.
  2.  
  3. Before servicing the vehicle, refer to the Precautions Section.
  4.  
  5. Make sure the ignition switch is OFF , then disconnect the negative battery cable..
  6.  
  7. Properly relieve the fuel system pressure, as outlined in this section.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  8.  
  9. Open fuel tank flap.
  10.  
  11. Remove the right rear wheel housing liner.
  12.  
  13. Remove the rear axle.
  14.  
  15. Drain fuel tank and clean fuel filler tube and surrounding area.
  16.  
  17. Remove mounting bolt and remove fuel flap unit with rubber gasket.
  18.  
  19. Remove securing bolt on filler neck.
  20.  
  21. Fold the rear seat bench forward.
  22.  
  23. Remove the cover plate from fuel gauge sensor and disconnect connector.
  24.  
  25. Remove the covers under fuel tank.
  26.  
  27. Disconnect return line (blue), supply line (black) and breather line (white) from their connection points, by pressing the buttons on the hose connections together.

    Click image to see an enlarged view

    Fig. Disconnect the return line (2 - blue), supply line (1 - black) and breather line (3 - white) at their connection points by pressing the buttons on the hose connections together

  28.  
  29. Remove tensioning strap. While doing so, support fuel tank using engine/transmission jack V.A.G 1383 A
  30.  
  31. Carefully lower fuel tank and remove it from the vehicle.
  32.  

To install:

  1. Installation is in reverse order of removal, note the following:
    1. Make sure ventilation and fuel lines are not kinked when installed.
    2.  
    3. Route fuel hoses kink-free.
    4.  
    5. Ensure fuel hoses are seated securely.
    6.  
    7. Secure fuel hoses with spring-type clamps.
    8.  
    9. Never interchange supply and return hose (return hose blue or blue markings, supply hose black).
      NOTE
      After installing fuel tank, check that the supply, return and breather lines are still clipped onto the fuel tank.

    10.  

  2.  

2.0L (Aba) Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the pressure in the fuel system.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Refer to the accompanying illustration for fuel tank removal and installation.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel tank-2000-02 models

  8.  

2.0L (Aeg/Avh/Azg/Bev) Engines




NOTE
This procedure requires the use of V.A.G. 1383 or equivalent Engine and Transaxle jack.


NOTE
The fuel extraction unit VAS 5190 is recommended for emptying the fuel tank.

  1. If the vehicle has a coded radio, make sure you have the anti-theft code before beginning the procedure.
  2.  
  3. Before servicing the vehicle, refer to the Precautions Section.
  4.  
  5. Make sure the ignition switch is OFF , then disconnect the negative battery cable..
  6.  
  7. Properly relieve the fuel system pressure, as outlined in this section.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  8.  
  9. Open fuel flap.
  10.  
  11. Remove right rear wheelhousing liner:
  12.  
  13. Drain fuel tank and clean fuel filter neck and surrounding area.
  14.  
  15. Remove securing bolt on filler neck.
  16.  
  17. Fold rear seat bench forward.
  18.  
  19. Remove cover from under fuel tank.
  20.  
  21. Remove the rear axle.
  22.  
  23. Remove the cover from fuel delivery unit.
  24.  
  25. Detach the 4- pin connector from flange (arrow).

    Click image to see an enlarged view

    Fig. Detach the 4- pin connector from flange (arrow)

  26.  
  27. Remove the cover from under the fuel tank (arrow)
    NOTE
    To disconnect the hoses, press buttons on hose couplings.



    Click image to see an enlarged view

    Fig. Remove the cover from under the fuel tank

  28.  
  29. Disconnect return hose (blue), supply hose (black) and breather hose (white) from the connecting point, by pressing the buttons on the hose couplings.

    Click image to see an enlarged view

    Fig. Disconnect return hose (2 -blue), supply hose (1 - black) and breather hose (3 - white) from the connecting point by pressing the buttons on the hose couplings

  30.  
  31. Plug or cap all lines so that fuel system is not contaminated by dirt etc.
  32.  
  33. Remove tensioning strap. When doing this support fuel tank with engine and transmission jack (V.A.G 1383 A or equivalent)
  34.  
  35. Carefully lower the fuel tank and remove it from the vehicle.
  36.  

To install:

  1. Installation is the reverse of the removal procedure, noting the following:
    1. Install breather and fuel hoses free of kinks.
    2.  
    3. Secure fuel hoses with spring-type clips
    4.  
    5. Make sure all fuel hoses are tight.
      NOTE
      Never interchange supply and return hoses (return line blue or blue markings, supply line black)


      NOTE
      After installing the fuel gauge sender, check that the supply return and breather lines are still clipped onto the fuel tank.

    6.  
    7. Use a scan tool to match the engine control module to throttle valve control module.
    8.  

  2.  

2.0L (Bbw) Engine




NOTE
This procedure requires the use of V.A.G. 1383 or equivalent Engine and Transaxle jack.


NOTE
The fuel extraction unit VAS 5190 is recommended for emptying the fuel tank. Contrary to the operating instructions the draining must not occur via the filler neck in this engine/vehicle or inner components will be damaged. Empty fuel tank only via the open flange.

  1. If the vehicle has a coded radio, make sure you have the anti-theft code before beginning the procedure.
  2.  
  3. Before servicing the vehicle, refer to the Precautions Section.
  4.  
  5. Open fuel flap.
  6.  
  7. Make sure the ignition switch is OFF , then disconnect the negative battery cable..
  8.  
  9. Properly relieve the fuel system pressure, as outlined in this section.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  10.  
  11. Fold the rear seat bench forward.
  12.  
  13. Remove the cover from fuel delivery unit.
  14.  
  15. Disconnect the 4-pin connector.
  16.  
  17. Unscrew the nuts and remove the flange.
  18.  
  19. Drain the fuel tank via the flange opening, with VAS 5190, or equivalent fuel extraction unit.
  20.  
  21. Install the flange again.
  22.  
  23. Remove the rear axle.
  24.  
  25. Remove the rear part of the exhaust system.
  26.  
  27. Remove right rear wheelhousing liner.
  28.  
  29. Clean the fuel filler neck and EVAP canister area.
  30.  
  31. Remove the tank flap unit with the rubber cup.
  32.  
  33. Pull the vacuum hose for fuel system leak detection pump off of the union.
  34.  
  35. Remove the 3-pin connector and disconnect wiring.
  36.  
  37. Disconnect the pressure hose.
    NOTE
    To unlock, press the safety ring (arrow) into the EVAP canister.



    Click image to see an enlarged view

    Fig. View of the rubber cup (1), fuel system leak detection pump vacuum hose (2), 3-pin connector (3), leak detection pump (4) and pressure hose (5)

  38.  
  39. Remove fuel system leak detection pump with detection pump air filter and bracket by pulling from center forward and then sliding downward.
  40.  
  41. Pull the breather lines and (4) off by pressing safety rings at EVAP canister (arrows) on upper and lower part together and unclipping breather line (3) out of clip (1).
  42.  
  43. Unfasten the bolts.

    Click image to see an enlarged view

    Fig. View of the breather lines (3, 4), clip (1) and bolts (2)

  44.  
  45. Unclip vacuum line at fuel tank.
  46.  
  47. Disconnect breather line.
  48.  
  49. Loosen spring-type clamp and pull supply hose off fuel line. Collect any leaking oil with a rag.

    Click image to see an enlarged view

    Fig. View of the vacuum line (1), breather line (2) and spring clamp (3)

  50.  
  51. Plug or cap the lines to avoid contamination of fuel system.
  52.  
  53. Support fuel tank with engine/transmission jack V.A.G 1383 A, or equivalent, the unscrew the bolts (arrows). Discard the bolts.
    NOTE
    To prevent damaging the vehicle-s paint place a cloth or rubber mat between fuel tank and jack.



    Click image to see an enlarged view

    Fig. After properly supporting the fuel tank, remove the bolts (arrows)

  54.  
  55. Carefully lower fuel tank.
  56.  

To install:

  1. Installation is the reverse of the removal procedure, noting the following:
    1. Tensioning strap rubber profile must not be damaged.
    2.  
    3. Replace the fuel tank mounting bolts with new bolts for installation.
    4.  
    5. Guide wirings on EVAP canister must be securely connected. Check for correct seat by tightening.
    6.  
    7. Use a scan tool to match the engine control module to throttle valve control module.
    8.  

  2.  

2.8L Engines




NOTE
This procedure requires the use of V.A.G. 1383 or equivalent Engine and Transaxle jack.


NOTE
The fuel extraction unit VAS 5190 is recommended for emptying the fuel tank.

  1. If the vehicle has a coded radio, make sure you have the anti-theft code before beginning the procedure.
  2.  
  3. Before servicing the vehicle, refer to the Precautions Section.
  4.  
  5. Make sure the ignition switch is OFF , then disconnect the negative battery cable..
  6.  
  7. Properly relieve the fuel system pressure, as outlined in this section.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  8.  
  9. Open fuel the flap.
  10.  
  11. Remove rear right wheel housing liner:
  12.  
  13. Remove the rear axle.
  14.  
  15. Drain fuel tank, clean fuel filler neck and surrounding area.
  16.  
  17. Unscrew mounting screw and remove tank flap unit with rubber cup.
  18.  
  19. Remove securing screws on filler neck.
  20.  
  21. Fold rear seat bench forward.
  22.  
  23. Remove cover from fuel delivery unit.
  24.  
  25. Remove 4-pin connector from flange (arrow).

    Click image to see an enlarged view

    Fig. Detach the 4-pin connector from the flange (arrow)

  26.  
  27. Remove the fuel tank cover, if equipped.

    Click image to see an enlarged view

    Fig. Remove the fuel tank cover (arrows)

  28.  
  29. Disconnect the return line (blue), supply line (black) and breather line (white) from their connecting points, by pressing the buttons on the couplings.

    Click image to see an enlarged view

    Fig. Disconnect the return line (2 - blue), supply line (1 - black) and breather line (3 - white) from their connecting points, by pressing the buttons on the couplings

  30.  
  31. Plug or cap the fuel lines to avoid contaminating the fuel system.
  32.  
  33. Support fuel tank with engine/transmission jack VAG 1383 A, or equivalent, then remove the tension strap.
  34.  
  35. Carefully lower fuel tank.
  36.  

To install:

  1. Installation is the reverse of the removal procedure, noting the following::
    1. Route breather and fuel hoses kink free.
    2.  
    3. Ensure tight fit of fuel hoses.
    4.  
    5. Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).
      NOTE
      After installing fuel gauge sender, check that the supply, return and breather pipes are still clipped onto the fuel tank.

    6.  
    7. Use a scan tool to match the engine control module to throttle valve control module:
    8.  

  2.  

 
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