How to Remove a VW Gas Tank

by Jeffrey Caldwell

The gas tank on a Volkswagen is a steel or plastic tank usually located at the rear of the vehicle below the trunk. Over time water or sediment can collect inside the tank and potentially clog the fuel system. Older steel tanks can also rust, meaning that small pieces of metal can break off and clog the fuel system. The fuel tank in a Volkswagen vehicle can be removed by the home mechanic. You must always take special precautions when servicing the fuel system, because gasoline and diesel fuel are both highly flammable.

Depressurizing the Fuel System

Step 1

Drain as much fuel as possible either using a hand or battery-operated siphon, or by driving the vehicle until most of the fuel is consumed. Never siphon gas or diesel fuel out of a fuel tank using your mouth.

Step 2

Locate the fuse panel cover. It will be located on the lower portion of the driver's side dash just above the gas pedal. Depress the to buttons on the face of the cover and remove it.

Step 3

Remove the two screws that secure the lower trim panel (its the panel that surrounds the fuse panel cover). Lower the trim panel.

Step 4

Remove the fuel pump relay. Consult the owner's manual to learn exactly which relay powers the fuel pump.

Step 5

Crank the engine for five to ten seconds. If the engine begins to run, allow it to run until the engine stalls out. Then crank the engine for an additional five to ten seconds.

Step 6

Disconnect the ground cable from the negative battery terminal by loosening the retaining bolt and pulling the clamp off the terminal. Secure the ground cable away from the battery so it cannot accidentally contact the negative terminal.

Step 7

Replace the fuel pump relay.

Step 8

Lift the lower trim panel into position and reinstall the two screws that retain it.

Disconnect the Fuel Pump Sender Unit

Step 1

Remove all items from the trunk.

Step 2

Remove the carpet panel from the center of the trunk floor. Pull out the tab on the rear of the panel.

Step 3

Unscrew the three screws that secure the access hole cover to the trunk floor. The access hole cover will be located to the right of the spare tire.

Step 4

Disconnect the wiring harness form the pump sending unit by squeezing the tabs on each side of the electrical connector.

Step 5

Label and disconnect the fuel supply and return lines by loosening the hose clamps and pulling the rubber lines off the fittings. There will be arrows on the fittings to tell you which is the return and which is the supply.

Removing a VW Gas Tank

Step 1

Position a hydraulic jack underneath the center of the fuel tank. Place a wood block between the jack and the tank to avoid damaging the tank. Raise the jack just enough to take the weight of the tank off the retaining straps.

Step 2

Move to the right rear wheel arch. Remove the screws that secure the fuel tank filler neck to the vehicle's body.

Step 3

Open the fuel filler door. Peel the rubber seal away from the vehicle's body.

Step 4

Remove the bolts that connect the tank retaining straps to the underside of the vehicle's body. You may need an assistant to steady the tank while you remove the retaining straps.