Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 738
– 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
⇒ “1.1.1 Overview - Fuel Tank, Vehicles with Multi-Link Rear
♦ 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 ⇒ Body Exterior; Rep. Gr. 66 ; Underbody Trim Pan‐
el .
♦ Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 42 ;
Wheel Bearing, Trailing Arm; Overview - Trailing Arm .
1.2.2
Fuel Tank, Removing and Installing, Ve‐
hicles with Multi-Link Rear Axle and
Leak Detection-Fuel Tank
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Trim Removal Wedge - 3409-
♦ Engine and Gearbox Jack - VAS6931-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
Removing
– Observe the safety instructions. Refer to
⇒ “1 Safety Precautions”, page 1
.
– Follow the guidelines for clean working conditions. Refer to
– Move the front seats all the way forward.
– Switch off the ignition.
– Remove the rear bench seat. Refer to ⇒ Body Interior; Rep.
Gr. 72 ; Rear Seats; Bench Seat / Single Seats, Removing
and Installing .
– Drain the fuel tank. Refer to
⇒ “1.3 Fuel Tank, Draining”, page 35
.
– Unclip the sealing flange cover -1- at the tabs -arrows- using
the -3409- .
– Unclip the grommet -1- downward out of the cover -2-.
– Guide the cover -2- on the wiring harness -3- toward the rear.
– Unlock and disconnect the connector -1- from the sealing
flange.
– If equipped, disengage the connector -2- for the parking heater
Metering Pump - V54- on the sealing flange and move it to the
side.
– Disconnect the connector -2-.
– Lift the tab -2- in the direction of the -arrow A- by using a finger
to reach between the floor panel and the fuel tank.
– At the same time, carefully pull the Fuel Pump Control Module
- J538- -1- out of the mount at the wiring harness -3- in the
direction of the -arrow B-.
– Remove the Fuel Pump Control Module - J538- toward the
inside between the fuel tank and the floor panel.
– 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 .
– Remove the fuel filler neck bolts -1 and 2-.
– Remove the breather lines -2 and 3- from the EVAP Canister.
– Release the connector -arrow- and remove.
– Unclip the wiring harness -1- from the brackets -arrows-.
– Remove the exhaust system rear section. Refer to ⇒ Rep. Gr.
26 ; Exhaust Pipes/Mufflers; Muffler, Removing and Installing .
– 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
.
– 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 .
– Press the lever -2- on the brake caliper in the direction of the
-arrow- and disengage the brake cable -1-.
– Press the tabs -3- together and remove the brake cable from
the bracket -4- on the brake caliper.
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