Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 742
Continuation for All Vehicles:
– Remove the bolt -5-.
– Remove the bracket for the exhaust system -arrow-.
– Remove the bolt -3- and remove the mounting strap -7-.
– Place the -VAS6931- under the fuel tank -1- to support it as
illustrated.
– Remove the bolts -2, 4 and 6-.
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 -1- using the -VAS6931- .
Installing
Install in reverse order of removal. Note the following:
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.
– Make sure the vent and fuel lines are routed without kinks.
– Make sure to guide the fuel filler neck correctly into the opening
in the body.
– Position the fuel tank together with the mounting strap on the
underbody using the -VAS6931- .
– Note the location of the mounting strap.
– Make sure the supply, return and breather lines are still clipped
to the fuel tank after the fuel tank has been installed.
– Note the correct installation location for the exhaust system
bracket. Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Muffler;
Overview - Muffler .
– Make sure the line connections are secure.
– Check the fit by pulling on it.
– 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 .
1.3
Fuel Tank, Draining
⇒ “1.3.1 Fuel Tank, Draining with Fuel Pump Installed”,
⇒ “1.3.2 Fuel Tank, Emptying with Fuel Pump Installed, Vehicles
with Engine Code CWVA”, page 38
⇒ “1.3.3 Fuel Tank, Draining When More than 3/4 Full”,
page 43
⇒ “1.3.4 Fuel Tank, Draining When Less Than 3/4 Full”,
page 44
⇒ “1.3.5 Fuel Tank less than 3/4 Full, Emptying, Vehicles with
1.3.1
Fuel Tank, Draining with Fuel Pump In‐
stalled
Special tools and workshop equipment required
♦ Trim Removal Wedge - 3409-
♦ Connector Test Set - VAG1594D-
♦ Injection Rate Comparison Meter Kit - Remote Cable -
VAG1348/3A-
♦ Vehicle Diagnostic Tester - Test Adapter - 5 Pin - VAS5565-
♦ Fuel Extractor VAS5190A - VAS5190-
♦ Fuel Extraction Unit - VAS5190A- (not illustrated) for E 85 -
fuel.
♦ Fuel Extraction Adapter - VAS5190-
Note
Use only the -VAS5190A- when extracting E 85 - fuel!
Note
If the -VAS5190- has a suction hose with a mounted tip, then re‐
place this with one that has a tip which screws on.
– Observe the safety instructions. Refer to
⇒ “1 Safety Precautions”, page 1
– Follow the guidelines for clean working conditions. Refer to
⇒ “3.1 Parking/Auxiliary Heater and Fuel System Clean Work‐
.
– Disconnect the fuel supply line -1-. 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.
– Collect leaking fuel with a cleaning cloth.
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