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Fuel tank, vehicles with four-wheel drive > < Assembly overview - fuel tank

Golf Mk5

Removing and installing fuel tank
Removing and installing fuel tank
Special tools and workshop equipment required
   
t  Torque wrench -V.A.G 1331/-
  W00-0427
t  Engine and gearbox jack -V.A.G 1383/A-
Removing
–  Note safety precautions before starting work → Chapter.
Observe rules for cleanliness → Chapter.
  Note
t  Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.
t  When lowering fuel tank, guide it carefully to prevent damage.
–  Disconnect earth strap from battery with ignition switched off → Electrical system; Rep. gr.27.
–  Fold rear seats forwards.
–  Detach carpet under seats and fold it back. → General body repairs, interior; Rep. gr.70
–  Remove cover from fuel delivery unit.
–  Pull connector off flange.
–  Remove fuel flap unit. → General body repairs, exterior; Rep. gr.55
–  Emptying fuel tank → Chapter.
–  Remove rear right wheel housing liner: → General body repairs, exterior; Rep. gr.66.
  W00-0120
–  Remove bolts from filler neck -arrows-.
  N20-0705
–  Disconnect fuel lines at front right of fuel tank.
  Note
Press buttons on hose couplings to do this.
–  If vehicle has supplementary heating, separate connector to metering pump and unclip wire. → Supplementary heating; Rep. gr.82
–  Remove bolts -A- and remove heat shield for fuel tank.
–  Support fuel tank using engine and gearbox jack -V.A.G 1383/A-.
  S20-0094
–  Remove securing bolts -arrows- for the fuel tank.
–  Slowly lower fuel tank and pull it forwards.
–  Tilt fuel tank to get it past rear axle.
Installing
Install in reverse order. In the process, note the following:
t  Install breather and fuel hoses free of kinks.
t  Ensure that fuel hose connections are tight.
t  Do not interchange supply and return lines (return line blue or with blue markings, supply line black).
t  Clip supply and return lines onto fuel tank.
  N20-10143

Fuel tank, vehicles with four-wheel drive > < Assembly overview - fuel tank