Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 741
– Check the ground cable for traces of oxidation on the connec‐
tors. Remove any oxidation if necessary.
– Check the installation position of the ground connection.
• The connector -2- must be securely attached to the metal ring
-3-.
• The contact -1- must be engaged in the fuel tank -4- and se‐
cured with the spacer -5-.
– Check the metal ring connection on the fuel filler neck to a bare
area on the body with an ohmmeter.
• Specified value is approximately 0 ohm.
• If the specified values is incorrect, then there is a risk of ex‐
plosion due to electrostatic discharge.
– Fill at least five liters of fuel in the fuel tank.
WARNING
There is a risk of the fuel tank exploding! After installing a new
or completely emptied fuel tank, fill it immediately with a mini‐
mum of five liters of fuel. Do not allow the fuel pump to run when
the fuel tank is completely empty.
Tightening Specifications
♦ Refer to
⇒ “1.1.2 Overview - Fuel Tank, Vehicles with FWD and Torsion
♦ Refer to ⇒ Body Interior; Rep. Gr. 72 ; Rear Seats; Bench
Seat / Single Seats, Removing and Installing .
♦ Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Overview -
Muffler .
♦ Refer to ⇒ Body Exterior; Rep. Gr. 55 ; Fuel Filler Door Unit;
Fuel Filler Door Unit, Removing and Installing .
♦ Refer to ⇒ Suspension, Wheels and Steering; Rep. Gr. 42 ;
Rear Axle; Rear Axle, Removing and Installing .
♦ Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Underbody Trim Pan‐
el .
1.2.4
Fuel Tank, Removing and Installing, Ve‐
hicles with Torsion Beam Rear Suspen‐
sion and Engine Code CWVA
Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Engine and Gearbox Jack - VAS6931-
Removing
– Observe the safety instructions. Refer to
⇒ “1 Safety Precautions”, page 1
.
– Follow the guidelines for clean working conditions. Refer to
– Drain the fuel tank. Refer to
⇒ “1.3 Fuel Tank, Draining”, page 35
.
– Move the front seats all the way forward.
– Switch off the ignition.
Golf Sportsvan:
– Remove the right rear seat. Refer to ⇒ Body Interior; Rep. Gr.
72 ; Rear Seats; Bench Seat / Single Seat, Removing and In‐
stalling .
– Partially loosen the cover -1- in the carpet at the separating
line -arrow-.
– Do not separate the cover completely from the carpet so that
later it will be installed correctly.
– Only loosen so far that the cover can be folded up.
– Fold up the cover in the direction of the -arrow-.
Golf and Golf Wagon:
– Remove the rear bench seat. Refer to ⇒ Body Interior; Rep.
Gr. 72 ; Rear Seats; Bench Seat / Single Seats, Removing
and Installing .
Continuation for All Vehicles:
– Unclip the sealing flange cover -1- at the tabs -arrows- using
the Trim Removal Wedge - 3409- .
– Unclip the grommet -1- downward out of the cover -2-.
– Guide the cover -2- on the wiring harness -3- toward the rear.
– Release and disconnect the connector -arrow-.
– Open the fuel filler door unit -2-.
– Clean the area around the fuel filler neck.
– Remove the cap -1- for the fuel filler neck.
Note
Seal the fuel filler neck opening with a clean plug to prevent any
dirt from getting in.
– Remove the fuel filler door unit -2-. Refer to ⇒ Body Exterior;
Rep. Gr. 55 ; Fuel Filler Door Unit; Fuel Filler Door Unit, Re‐
moving and Installing .
– Remove the right rear wheel. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 44 ; Wheels, Tires; Changing a Wheel .
– Remove the right rear wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Overview - Rear
Wheel Housing Liner .
– Remove the rear underbody trim panel. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 66 ; Underbody Trim Panel; Underbody Trim
Panels, Removing and Installing .
– Disconnect the vent lines -1- and -2- from the EVAP canister.
Disconnect the connector couplings. Refer to
⇒ “4.1 Connector Couplings, Disconnecting”, page 62
– Unclip the breather line from bracket -arrows-.
– Unclip the breather lines -1- at the bracket -arrow-.
– Remove the rear axle. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 42 ; Rear Axle; Rear Axle, Removing and
Installing .
– Remove the exhaust system rear section. Refer to ⇒ Rep. Gr.
26 ; Exhaust Pipes/Mufflers; Overview - Muffler .
– Remove the fuel filler neck bolts -1 and 2-.
– Remove the fuel line -1- from the underbody. Disconnect the
connector couplings. Refer to
⇒ “4.1 Connector Couplings, Disconnecting”, page 62
.
WARNING
The fuel line is under pressure.
Fuel poses a risk of injury to the eyes and skin.
Wear protective eyewear and protective clothing to avoid injury
and contact with skin. Place a cleaning cloth around the con‐
nection point before loosening hose connections. Carefully
open the connection point to release the pressure.
– Disconnect the breather line -2-. Disconnect the connector
couplings. Refer to
⇒ “4.1 Connector Couplings, Disconnecting”, page 62
.
Vehicles with Parking Heater:
– Remove the fuel line -1- from the parking heater. Disconnect
the connector couplings. Refer to
⇒ “4.1 Connector Couplings, Disconnecting”, page 62
.
– If equipped, remove the rear underbody trim panel. Refer to
⇒ Body Exterior; Rep. Gr. 66 ; Underbody Trim Panel; Un‐
derbody Trim Panels, Removing and Installing .
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