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

Axle and FWD”, page 6

♦ 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

⇒ “3.1 Parking/Auxiliary Heater and Fuel System Clean Work‐

ing Conditions”, page 4

 .

– 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.