volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Installing > < Removing and installing fuel tank

Golf Mk4

Removing
Removing
  Note
t  Note safety precautions before beginning work → Chapter.
t  We advise using fuel extractor -VAS 5190- to drain fuel tank.
–  First check whether a coded radio is fitted. If so, obtain anti-theft coding.
–  With ignition switched off, disconnect battery earth strap.
–  Open tank flap unit.
–  Remove rear right wheel housing liner → Rep. Gr.66.
–  Drain fuel tank and clean area around fuel filler neck.
–  Remove securing bolts and remove tank flap unit with rubber cup.
–  Remove securing bolt on filler neck.
–  Fold rear bench seat forward.
–  Remove cover from fuel gauge sender -G- and unplug connector.
–  Remove covers from under fuel tank.
Vehicles with front wheel drive
–  Remove rear axle: → Rep. Gr.42
Vehicles with all-wheel drive
–  Remove rear axle: → Rep. Gr.42
Continuation for all vehicles
  WARNING
Fuel system is under pressure! Before loosening hose connections, wrap a cloth around connection. Then release pressure by carefully pulling hose off connection.
   
–  Disconnect return line -2- (blue), supply line -21- (black) and breather line -3- (white) at connection.
  Note
Press circlip in to release fuel lines.
Vehicles with all-wheel drive
  A20-0097
–  Remove securing nuts/bolts -arrows-.
Continuation for all vehicles
–  Unscrew securing straps. When doing this, support fuel tank with engine and gearbox jack -V.A.G 1383 A-.
–  Lower fuel tank.
  N20-0276

Installing > < Removing and installing fuel tank