Volkswagen Workshop Service and Repair Manuals

Removing and installing fuel tank Special tools and workshop equipment required

t  Torque wrench (5…50 Nm) -V.A.G 1331-

t  Engine and gearbox jack -V.A.G 1383 A- Removing fuel tank: –  Note safety precautions before beginning work → Chapter. –  Unscrew tank flap unit securing bolt and remove tank flap unit → General body repairs, exterior; Rep. Gr.55. –  Drain fuel tank and clean fuel filler neck and surrounding area. –  Remove rear seat bench (Golf Plus: rear right seat) → General body repairs, interior; Rep. Gr.72.

–  Remove covers from fuel pump unit.

–  Pull off connector -arrow-.   Note For vehicles with auxiliary heater the metering pump -V54- connector must be separated additionally. –  Remove right rear wheel. –  Remove rear right wheel housing liner → General body repairs, exterior; Rep. Gr.66.

–  Unbolt fuel filler neck from body -arrows-. –  Unclip electrical line from filler neck. –  Remove centre and rear silencers.   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.

–  Disconnect breather hose -1- (white) and supply hose -2- (black) at connecting point.   Note t  Press in securing ring to release fuel lines. t  Vehicles with auxiliary heater, the fuel line of the metering pump -V54- must also be separated.

–  Remove securing strap and securing bolts -arrows-. When doing this, support fuel tank with engine and gearbox jack -V.A.G 1383 A-. –  Lower fuel tank. Installing fuel tank: Installation is performed in the reverse sequence. In the process, note the following: t  To secure the securing straps for the fuel tank, only bolts with loose washers must be used. If different bolts are used, the securing straps may twist during tightening. Bolts → ETKA (electronic parts catalogue). t  Install breather and fuel lines free of kinks. t  Do not interchange supply and return line (return line blue or with blue markings, supply line black). t  Ensure wiring/line connections are secured properly by pulling back. t  Check earth connection on fuel tank and body to filler neck. t  After installing fuel tank, check that the supply, return and breather lines are still clipped onto the fuel tank. t  Bleed fuel system → Chapter.