Remove the Passat Fuel Tank

• 1). Detach and isolate the negative battery cable to prevent injuries, like electrocution, and accidents, like fires, from occurring.
  
  
• 2). Open the flap for the fuel tank and remove the housing liner for the right rear wheel. Also, take off the rear axle.
  
  
• 3). Empty the fuel into a fuel extraction unit like the VAS 5190. To prevent accidents, clean the fuel filter tube and the area around it.
  
  
• 4). Use a wrench to loosen and detach the mounting bolt. You also need to remove the fuel flap unit rubber gasket and the bolt that holds the filler neck in place.
  
  
• 5). Access the fuel gauge sensor, so you can disconnect it. To do this, you need to fold the rear bench seat of the car. Also, remove the Passat fuel tank covers, which should be under the fuel tank. On 2.0 L (Aeg/Avh/Azg/Bev) engines, you also need to take off the fuel delivery unit and the four-pin flange connector.
  
  
• 6). Release the hose connections by pressing the buttons together and remove the blue return line, the black supply line and white breather line.
  
  
• 7). Support the fuel tank with a V.A.G. 1383 A jack and take off the tensioning strap. Gently remove the fuel tank from the body of the car.
  
  

Install the New Passat Fuel Tank

• 1). Insert the new Passat fuel tank.
  
  
• 2). Reassemble the components you removed when you took off the fuel tank. To do this, reverse the steps you used previously.
  
  
• 3). Ensure the fuel hoses have a clear route. They should not have kinks, bends or other obstructions.
  
  
• 4). Verify the hoses connect to the proper place and that each hose attaches securely with a spring-type clamp.