Volkswagen Golf Service & Repair Manual: Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

Volkswagen Golf Service & Repair Manual / Fuel supply system - Petrol engines / Fuel supply, gas operation / Fuel tank / Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

Special tools and workshop equipment required

Torque wrench -V.A.G 1331-

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

Removal wedge -3409-

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

Engine and gearbox jack -V.A.G 1383 A-

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

Engine and gearbox jack -VAS 6931-

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

Torque wrench -V.A.G 1332-

Removing

–	Observe safety instructions → Chapter.

–	Observe rules for cleanliness → Chapter.

–	Move front seats to foremost position.

–	Switch off ignition.

–	Remove rear bench seat → General body repairs, interior; Rep. gr.72.

–	Draining fuel tank → Chapter

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Unclip cover -1- for flange at retaining tabs -arrows-, using removal wedge -3409-.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Unclip sealing grommet -1- downwards from cover -2-.

–	Push cover -2- back along wiring harness -3-.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Release and pull off connector -1- on sealing flange.

–	If fitted, detach connector -2- for metering pump -V54- of auxiliary heater on sealing flange and lay connector aside.

–	Release and pull off connector -2-.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Press up tab -2- in -direction of arrow A-; to do so, reach between floor panel and fuel tank with your finger.

–	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-.

–	Guide fuel pump control unit -J538- out towards interior between fuel tank and floor panel.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Open tank flap unit -2-.

–	Clean area around fuel filler neck.

–	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.

–	Remove tank flap unit -2- → General body repairs, exterior; Rep. gr.55.

–	Remove rear right wheel → Running gear, axles, steering; Rep. gr.44.

–	Remove rear right wheel housing liner → General body repairs, exterior; Rep. gr.66.

–	Remove rear underbody cladding → General body repairs, exterior; Rep. gr.66.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Unscrew bolts -1- and -2- for fuel filler neck.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Pull breather lines -1- and -2- off activated charcoal filter.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Release and pull off connector -arrow-.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Unclip wiring harness -1- from retainers -arrows-.

–	Remove rear section of exhaust system → Rep. gr.26.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	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.

–	Disconnect breather line -2-. Separate plug-in connectors → Chapter.

–	If rear underbody cladding is fitted, remove it → General body repairs, exterior; Rep. gr.66.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Push lever -2- on brake caliper in -direction of arrow-, and detach handbrake cable -1-.

–	Press together locking lugs -3-, and remove handbrake cable from bracket -4- on brake caliper.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Unclip handbrake cable -4- from retainer -arrow A-.

–	Pull handbrake cable out of guide -arrow B- on retainer -3-.

–	Unscrew bolts -2-, and swing trailing arm -1- downwards.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Remove bolt -4-.

–	Remove bracket for exhaust system.

–	Unscrew bolt -2- and remove securing strap.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Place engine and gearbox jack under fuel tank -1- to support it.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Unscrew bolts -1- and -3-.

Note

For reasons of clarity, the fuel tank is shown without the engine and gearbox jack -V.A.G 1383 A-.

The aid of a 2nd mechanic is required to remove the fuel tank.

–	Lower fuel tank with engine and gearbox jack -V.A.G 1383 A-.

–	Lower fuel tank by turning it sideways.

–	Observe lines to activated charcoal filter (unclip them, if necessary).

–	Guide filler neck out between rear axle and body.

Installing

Install in reverse order. Observe the following:

–	Guide filler neck in between rear axle and body.

Note

Separate plug-in connectors → Chapter.

–	If metering pump -V54- is fitted, ensure that it is securely fastened to bracket.

–	Make sure that the filler neck of the fuel tank is correctly inserted into the opening in the body.

–	Install breather and fuel lines free of kinks.

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

–	Position the fuel tank together with securing strap on underbody, using the engine and gearbox jack -V.A.G 1383 A-.

–	Make sure bracket for exhaust system is seated correctly → Rep. gr.26.

–	Note position of securing strap.

–	Ensure that line connections are tight.

–	Ensure connections are secured properly by pulling.

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

–	Check whether there are signs of oxidation on the earth wire of the connectors, remove if necessary.

–	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-.

–	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.

–	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.

Specified torques

→ Chapter „Assembly overview - fuel tank, vehicles with multi-link rear suspension“

→ General body repairs, interior; Rep. gr.72

→ Rep. gr.26

→ General body repairs, exterior; Rep. gr.55

→ General body repairs, exterior; Rep. gr.66

→ Running gear, axles, steering; Rep. gr.42

Removing and installing fuel tank, vehicles with multi-link rear suspension and fuel tank leakage diagnosis function

Assembly overview - fuel tank, vehicles with four-wheel drive

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