Volkswagen Golf Service & Repair Manual: Removing and installing fuel tank, vehicles with multi-link rear suspension
and fuel tank leakage diagnosis function
| Special tools and workshop equipment
required |
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| Torque wrench -V.A.G 1331- |
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| Engine and gearbox jack -V.A.G 1383 A- |
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| Engine and gearbox jack -VAS 6931- |
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| Torque wrench -V.A.G 1332- |
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Observe safety instructions
→ Chapter. |
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Observe rules for cleanliness
→ Chapter. |
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Move front seats to foremost position. |
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Remove rear bench seat
→ General body repairs, interior; Rep. gr.72. |
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Draining fuel tank
→ Chapter |
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Unclip cover -1- for flange at
retaining tabs -arrows-, using
removal wedge -3409-. |
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Unclip sealing grommet -1-
downwards from cover -2-. |
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Push cover -2- back along
wiring harness -3-. |
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Release and pull off connector -1-
on sealing flange. |
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If fitted, detach connector -2-
for metering pump -V54- of auxiliary heater on sealing flange
and lay connector aside. |
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Release and pull off connector -2-. |
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Press up tab -2- in
-direction of arrow A-; to do so,
reach between floor panel and fuel tank with your finger. |
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At the same time, carefully pull fuel pump control unit
-J538--1- out of mounting
-in direction of arrow B- by
grasping hold of wiring harness -3-. |
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Guide fuel pump control unit -J538- out towards interior
between fuel tank and floor panel. |
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Open tank flap unit -2-. |
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Clean area around fuel filler neck. |
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Unscrew cap -1- for fuel filler
neck. |
 Note
| In order to prevent the ingress of dirt, seal the opening of
the fuel filler neck with a clean plug. |
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Remove tank flap unit -2-
→ General body repairs, exterior; Rep. gr.55. |
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Remove rear right wheel
→ Running gear, axles, steering; Rep. gr.44. |
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Remove rear right wheel housing liner
→ General body repairs, exterior; Rep. gr.66. |
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Remove rear underbody cladding
→ General body repairs, exterior; Rep. gr.66. |
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Unscrew bolts -1- and
-2- for fuel filler neck. |
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Pull breather lines -1- and
-2- off activated charcoal filter. |
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Release and pull off connector -arrow-. |
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Unclip wiring harness -1- from
retainers -arrows-. |
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Remove rear section of exhaust system
→ Rep. gr.26. |
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Disconnect fuel line -1- on
underbody. Separate plug-in connectors
→ Chapter. |
The fuel system is pressurised.Risk of injury due to fuel which may
spurt out.Wear eye protection.Wear protective gloves.Release pressure:
place clean cloth around connection and carefully open connection.
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Disconnect breather line -2-.
Separate plug-in connectors
→ Chapter. |
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If rear underbody cladding is fitted, remove it
→ General body repairs, exterior; Rep. gr.66. |
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Push lever -2- on brake caliper
in -direction of arrow-, and detach
handbrake cable -1-. |
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Press together locking lugs -3-,
and remove handbrake cable from bracket
-4- on brake caliper. |
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Unclip handbrake cable -4- from
retainer -arrow A-. |
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Pull handbrake cable out of guide
-arrow B- on retainer -3-. |
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Unscrew bolts -2-, and swing
trailing arm -1- downwards. |
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Remove bracket for exhaust system. |
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Unscrew bolt -2- and remove
securing strap. |
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Place engine and gearbox jack under fuel tank
-1- to support it. |
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Check whether there are signs of oxidation on the earth wire
of the connectors, remove if necessary. |
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Check installation position of earth connection. |
| Ensure that connector -2- is
seated securely on metal ring -3-. |
| Contact tab -1- must be
attached to fuel tank -4- and
secured with spacer bush -5-. |
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Check contact of metal ring on fuel filler neck by measuring
resistance between ring and bare metal on body using an
ohmmeter. |
| Specification: approx. 0 ohm. |
| If the specification is not attained, there is a risk of
explosion due to electrostatic discharge. |
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Fill fuel tank with at least 5 litres of fuel. |
Risk of explosion of fuel tank caused by fuel pump activation.Risk of
severe injuries and burns.If a new or completely empty fuel tank has
been installed, fill it immediately with at least 5 litres of fuel.
| → Chapter „Assembly overview - fuel tank, vehicles with
multi-link rear suspension“ |
| → General body repairs, interior; Rep. gr.72 |
| → General body repairs, exterior; Rep. gr.55 |
| → General body repairs, exterior; Rep. gr.66 |
| → Running gear, axles, steering; Rep. gr.42 |
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1 -
Breather line
To activated charcoal filter
Do not kink
Clipped onto fuel tank
To pull off, press rele ...
Special tools and workshop equipment required
Removal wedge -3409-
Remote control -V.A.G 1348/3A-
Test instrument adapter/DSO (5-pin) -V ...
Other materials:
O-ring
Use only O-rings that are resistant to refrigerant R134a and
related refrigerant oils. O-rings are no longer colour-coded.
Coloured and black O-rings are used.
Check that the O-rings used have the correct internal
diameters.
...
Safety precautions when using testing and measuring instruments during a
road test
Please note the following points if test and measuring
equipment has to be used while test driving the vehicle:
WARNING
Risk of accidents due to distraction and inadequate
securing of test and ...
Vacuum system
Vacuum pump for brake servo, diesel
vehicles
Vacuum pump for 4-cylinder diesel engine (1.6 l, common
rail):
The vacuum pump is installed in the oil pump.
–
Removing and installing vac ...
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Assembly overview - fuel tank, vehicles with four-wheel drive
Emptying fuel tank when fuel pump is intact