Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 740
– Unlock and disconnect the connectors -1- from the sealing
flange.
– If equipped, release the connector -2- for the Metering Pump
- V54- and remove it.
– Disconnect the connector -2-.
– Lift the tab -2- in the direction of the -arrow A-.
– To do so, reach a finger 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 .
– 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 .
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.
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