Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 737
– 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-.
– 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 and 2- at the bracket -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
.
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 .
– 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.
– 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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