Removing and installing fuel tank, vehicles with front-wheel drive and multi-link rear suspension — VW

🧭 Before you start

Fits: VW Golf VII Variant (BA), VW Golf Sportsvan (AM1, 2014–2020), VW Golf VII (5G, 2012–2020)

• Opens: fuel

Don't miss

• Do not detach cover completely from floor covering in order to ensure it is reinstalled in the correct installation position.
• In order to prevent the ingress of dirt, seal the opening of the fuel filler neck with a clean plug.
• Mark installation position between wheel bearing housing (1) and trailing arm (2).
• Make a mark on the trailing arm in the area shown (arrow).
• For reasons of clarity, the fuel tank is shown without the engine and gearbox jackV.A.G 1383 A.The aid of a 2nd mechanic is required to remove the fuel tank.

🔧 Engine codes this applies to

📋 Procedure

1. Observe safety instructions .
2. Observe rules for cleanliness .
3. Draining fuel tank
4. Move front seats to foremost position.
5. Switch off ignition.

6. Remove right rear seat General body repairs, interior72Rear seats; Removing and installing bench seat/individual seats.
7. Detach cover (1) in floor covering partly at parting line (arrow).
8. Do not detach cover completely from floor covering in order to ensure it is reinstalled in the correct installation position.
9. Detach it just enough that the cover can be folded upwards.
10. Fold up cover in (direction of arrow).
11. Remove rear bench seat General body repairs, interior72Rear seat; Removing and installing bench seat / individual seats.
12. Unclip cover (1) for flange at retaining tabs (arrows), using removal wedge3409.
13. Unclip sealing grommet (1) downwards from cover (2).
14. Guide cover (2) along wiring harness (3) backwards.
15. Release and pull off connectors (1) and (2) on sealing flange.
16. If installed, release and pull off connector (3) for metering pump V54.
17. Push tab (2) up in (direction of arrow A).
18. To do this, reach in with your finger between the floor plate and fuel tank.
19. At the same time, carefully pull fuel pump control unit J538(1) out of mounting (in direction of arrow B) by grasping hold of wiring harness (3).
20. Guide fuel pump control unit J538 out towards interior between fuel tank and floor panel.
21. Open tank flap unit (2).
22. Clean area around fuel filler neck.
23. Unscrew cap (1) for fuel filler neck. [Note: In order to prevent the ingress of dirt, seal the opening of the fuel filler neck with a clean plug.]
24. Remove tank flap unit (2)General body repairs, exterior55Tank flap unit; Removing and installing tank flap unit.
25. Remove rear right wheel Running gear, axles, steering44Wheels, tyres; Wheel change.
26. Remove rear right wheel housing liner General body repairs, exterior66Wheel housing liner; Assembly overview - rear wheel housing liner.
27. Unscrew bolts (1) and (2) for fuel filler neck.
28. Remove rear part of exhaust system 26Exhaust system/silencer; Assembly overview - silencers.
29. Disconnect fuel line (1) on underbody. Separate plug-in connectors .
30. ⚠ The fuel line is under pressure.Risk of injury to eyes and skin from fuel.Wear eye protection and protective clothing to avoid eye injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully opening the connection point. — Disconnect fuel return line (2). Separate plug-in connectors .
31. Disconnect fuel line (1) to auxiliary heater. Separate plug-in connectors .
32. Mark installation position between wheel bearing housing (1) and trailing arm (2).
33. To do this, use a suitable marker pen.
34. Make a mark on the trailing arm in the area shown (arrow).
35. Unclip wiring harness (2) from trailing arm (1)(arrows).
36. Unscrew bolts (3), and swing trailing arm (1) downwards.
37. Push lever (2) on brake caliper in (direction of arrow), and detach brake cable (1).
38. Press together locking lugs (3), and remove brake cable from bracket (4) on brake caliper.
39. Unclip handbrake cable, and pull it out of retainer.
40. Unscrew bolts (3), and swing trailing arm (1) downwards.
41. If rear underbody cover is fitted, remove it General body repairs, exterior66Underbody cover; Assembly overview - underbody covers.
42. Remove bolt (4).
43. Remove bracket for exhaust system.
44. Unscrew bolt (2) and remove securing strap.
45. Place engine and gearbox jackV.A.G 1383 A underneath for support and prop up fuel tank as shown in illustration.
46. Unscrew bolts (1) and (3). [Note: For reasons of clarity, the fuel tank is shown without the engine and gearbox jackV.A.G 1383 A.The aid of a 2nd mechanic is required to remove the fuel tank.]
47. Lower fuel tank with engine and gearbox jackV.A.G 1383 A.
48. Lower fuel tank by turning it sideways.
49. Guide filler neck out between rear axle and body. [Note: Separate plug-in connectors .]
50. Observe installation position of vent nipple (1) on fuel tank (2).
51. Install breather and fuel lines free of kinks.
52. Guide filler neck in between rear axle and body.
53. If fitted, check that metering pump V54 is firmly seated.
54. Make sure that the filler neck of the fuel tank is correctly inserted into the opening in the body.
55. Position the fuel tank together with securing strap on underbody, using the engine and gearbox jackV.A.G 1383 A.
56. Make sure the bracket for the exhaust system is seated correctly 26Exhaust pipes/silencers; Assembly overview - silencers.
57. Note position of securing strap.
58. Ensure that line connections are tight.
59. After installing fuel tank, check that the supply, return and breather lines are still clipped onto the fuel tank.
60. Align wheel bearing housing (1) and trailing arm (2) in relation to each other.

Other VW procedures

• Removing and installing exhaust flap control unit J883 · 2 torque figures
• Removing and installing radiator cowling · 1 torque figures
• Emptying tank for reducing agent
• Removing and installing fuel pressure regulating valve, version 1
• Removing and installing upper toothed belt guard, vehicles with SCR system
• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures