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

1 - Breather line To activated charcoal filter Do not kink Clipped onto fuel tank To pull off, press rele ...

Emptying fuel tank when fuel pump is intact

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:

Overview of fitting locations - airbag crash sensors
1 - Side airbag crash sensor, front passenger side -G180- Location: in door Safety precautions when handling crash sensors (pressure sensors) for front side airbags → Chapter Removing and installing → Chapter 2 -&n ...

Checking steering column for damage
Visual check – Check all steering column parts for damage. Checking function – Check that steering column turns smoothly and easily. – Check whe ...

Assembly overview - side spoiler
1 - Side spoiler 2 - Adhesive strips Part of side spoiler 3 - Rear window 4 - Removal aid For protective film of adhesive tape 5 - Bonding surface ...