Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 739
– Unclip the parking brake cable -4- from the bracket
-arrow A-.
– Pull the parking brake cable out of the guide -arrow B- on the
bracket -3-.
– Remove the bolts -2- and pivot the trailing arm -1- downward.
– Remove the bolt -4-.
– Remove the bracket for the exhaust system.
– Remove the bolt -2- and remove the mounting strap.
– Place the -VAS6931- under the fuel tank for support.
– Remove the bolts -1 and 3-.
Note
♦
To improve clarity, the fuel tank is shown without the -
VAS6931- .
♦
A second technician is required to remove the fuel tank.
– Lower the fuel tank using the -VAS6931- .
– By turning it accordingly, lower the fuel tank sideways.
– Pay attention to the lines to the EVAP canister, unclipping
them if necessary.
– Guide the filler neck out between the rear axle and the body.
Installing
Install in reverse order of removal. Note the following:
– Guide the filler neck between the rear axle and the body.
Note
Disconnect the connector couplings. Refer to
⇒ “4.1 Connector Couplings, Disconnecting”, page 62
– If equipped, make sure the Metering Pump - V54- is seated
securely on the bracket.
– Make sure to guide the fuel filler neck correctly into the opening
in the body.
– Make sure the vent and fuel lines are routed without kinks.
– Make sure the supply, return and breather lines are still clipped
to the fuel tank after the fuel tank has been installed.
– Position the fuel tank together with the mounting strap on the
underbody using the -VAS6931- .
– Note the correct installation location for the exhaust system
bracket. Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Muffler;
Overview - Muffler .
– Note the location of the mounting strap.
– Make sure the line connections are secure.
– Check the fit by pulling on it.
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– 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 .
1.2.3
Fuel Tank, Removing and Installing, Ve‐
hicles with Torsion Beam Rear Suspen‐
sion
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 -3409- .
– Unclip the grommet -1- downward out of the cover -2-.
– Guide the cover -2- on the wiring harness -3- toward the rear.
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