Volkswagen Golf Workshop Service and Repair Manuals

Removing

• ‒ Detach battery earth strap.
• ‒ Empty fuel tank
• ‒ Remove cover in right rear wheel housing.
• ‒ → Detach large vent pipe -3- from filler neck.
• ‒ Pull gravity valve downward (pipes -1- and -2- remain connected).

Engine Codes: DX, JH, KT

• ‒ → Detach fuel pump bracket from body and lower pump.
• ‒ Remove fuel tank bolt -3-.
• ‒ Detach hose -1- from fuel pump.
• ‒ Detach hose -2- from the return pipe.

Engine Code: 2H

• ‒ → Remove fuel filter -2- with bracket.
• ‒ Detach hose -1- from supply pipe.
• ‒ Remove fuel pump -3- from bracket and pull hose -4- off fuel pump.
• ‒ Detach hose -5- from return pipe.

Continuation for all vehicles

• ‒ → Disconnect brake hoses at rear axle on both sides -black arrows-.
• ‒ Detach rear axle from body on both sides -White arrows- swing down and allow it to be caught by handbrake cable guides.
• ‒ Unhook rear silencer support lugs.
• ‒ Detach hose from fuel tank filler neck.
• ‒ Support tank with V.A.G 1383, detach from body and lower carefully.
• ‒ Remove connector from fuel gauge sender.

• ‒ Detach vent pipes from tank.
• ‒ Remove fuel tank.

Installation:

• ‒ To install tank follow steps in reverse order.
• ‒ Bleed brake system.

Notes:

• ◆ When connecting the hose clips for the vent hoses, turn them so that they do not come into contact with the body.
• ◆ When a new fuel tank is installed, foam rubber strips should be glued to same positions as on tank wich was removed. After installation, it is imperative that tank be treated with durable undercoating -D35-.
• ◆ The fuel filler neck on vehicles with catalyst using unleaded fuel has smaller opening and a flap in filler neck.