Volkswagen Golf/Jetta 2 manual

Fuel tank - removal and refitting
Fuel and exhaust systems - carburettor models / Fuel tank - removal and refitting


Warning: The fuel tank must always be removed in a well ventilated area and never over a pit
Removal
1 Disconnect the battery negative lead.

2 Siphon or pump all the fuel from the tank (there is no drain plug) .

3 Lift the floor covering from the luggage compartment then remove the circular sender unit cover (see illustration).

7.3 Fuel tank and associated components
7.3 Fuel tank and associated components

4 Disconnect the wiring plug from the top of the sender unit, also the fuel feed (to pump) and return (from fuel reservoir) hoses.

5 Jack up the rear of the vehicle and support it on axle stands (see УJacking and vehicle supportФ). Chock the front wheels, remove the right-hand side rear wheel.

6 Disconnect the breather hose from the filler neck (see illustration).

7.6 Fuel filler breather valve and hose
7.6 Fuel filler breather valve and hose

7 Disconnect the expansion tank-to-filler neck hose and breather pipe.

8 Disconnect the filler neck funnel which is secured by a large C-clip.

9 Support the fuel tank with a trolley jack and length of wood. Unscrew the retaining nuts and bolts, detach the straps (see illustration) and lower the tank to the ground. On GTi models, it will also be necessary to detach the side protector plate.

7.9 Fuel tank retaining strap-to-floor bolts
7.9 Fuel tank retaining strap-to-floor bolts

10 If the expansion reservoir is to be removed, undo the retaining bolt and lower it from the wheel arch.

11 If the tank is contaminated with sediment or water, remove the gauge sender unit and swill the tank out with clean fuel. If the tank is damaged or leaks, it should be repaired professionally or renewed.

Refitting
12 Refitting is a reversal of removal. Make sure that the rubber packing strips are fitted to the retaining straps. Refit the hoses free of any kinks.


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