volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Installing fuel tank > < Removing and installing fuel tank

Golf Mk5

Removing fuel tank
Removing fuel tank
–  Note safety precautions before beginning work → Chapter.
  Note
Before disconnecting battery, open fuel tank flap and if necessary use wheel lock adapter from luggage compartment.
–  First check whether a coded radio is fitted. If so, obtain anti-theft coding.
–  Disconnect earth strap from battery with ignition switched off → Electrical system; Rep. Gr.27.
If necessary, empty fuel tank using fuel extractor -VAS 5190-. → Chapter
–  Remove right rear wheel.
–  Remove rear right wheel housing liner. → General body repairs, exterior; Rep. Gr.66.
–  Unscrew securing bolts and remove tank flap unit. → General body repairs, exterior; Rep. Gr.55
   
–  Unscrew filler neck from body -arrows- and unclip electrical wire from filler neck.
–  Remove bench seat → General body repairs, interior; Rep. Gr.72.
  N20-0705
–  Remove covers and separate electrical connectors -arrows-.
–  Remove middle and rear silencers.
  N20-10137
–  Secure exhaust system to underbody using wire.
–  Remove rear propshaft → Manual gearbox; Rep. Gr.39
  WARNING
The fuel supply line is under pressure! Wear eye protection and protective clothing to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
  N20-10147
–  Pull off adapter lead on four-wheel drive control unit -J492-.
  N20-10146
–  Support fuel tank using engine and gearbox jack -V.A.G 1383 A- and unscrew tensioning straps and securing bolts.
–  Slowly lower fuel tank.
  Note
The filler neck must be “guided out” between body and rear axle. To do this, take the fuel tank off engine and gearbox jack -V.A.G 1383 A- with the assistance of a 2nd mechanic.
  N20-10136

Installing fuel tank > < Removing and installing fuel tank