Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



Rabbit (Except Pick-up), Golf, Jetta and 1975-84 Scirocco
  1. Disconnect the battery.
  2.  
  3. Remove the drain plug and empty the tank. Disconnect the remove fuel pump if removal of the pump is necessary to gain clearance to remove the tank.
  4.  
  5. Disconnect the parking brake cables at the parking brake lever.
  6.  
  7. If required, disconnect and plug the rear brake lines.
  8.  
  9. If required, remove the rear axle mounting nuts and pull the rear axle down.
  10.  
  11. Disconnect the sending unit ground wire, gauge wire and transfer pump wiring.
  12.  
  13. Loosen the clamps and pull off the fuel line(s).
  14.  

If more than one fuel line attaches to the sending unit, mark the lines to avoid confusion when assembly.

  1. Disconnect any other breather lines. Disconnect the filler pipe.
  2.  
  3. Remove the rubber exhaust hangers if they hinder removal of the fuel tank.
  4.  
  5. Remove the fuel tank straps and allow the tank to come down far enough to see if there are any other vent hoses to be disconnected.
  6.  
  7. After removing all vent hoses, remove the tank.
  8.  

Many earlier models do not have these vent lines.

To install:
  1. Raise and support the tank. If you have to connect any vent lines, do so at this time, before securing the tank straps. Make sure that all breather and vent lines are not kinked. Use new clamps on all connections.
  2.  
  3. Install the rubber exhaust hangers, if they were removed.
  4.  
  5. Connect the filler pipe and any breather lines.
  6.  
  7. Connect the fuel lines. Use new clamps on all connections.
  8.  
  9. Connect the transfer pump, gauge and sending unit wires.
  10.  
  11. Install the rear axle and tighten the rear axle nut to specification.
  12.  
  13. Connect the rear brake lines and bleed the brakes.
  14.  
  15. Connect the parking brake cables to the lever and adjust.
  16.  
  17. Install the fuel pump.
  18.  
  19. Install the drain plug and fill the tank.
  20.  
  21. Connect the negative battery cable.
  22.  

Rabbit Pick-up

See Figure 1

The fuel tank is located to the rear of the cab.

  1. Disconnect the battery.
  2.  
  3. Drain the fuel from the tank using a conventional siphon.
  4.  
  5. Remove and match mark all hoses from the tank, except for the breather hose in the sending unit.
  6.  
  7. Remove the wires from the sending unit.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Fuel tank assembly used on the Rabbit Pick-up. Other models are similar

  1. Loosen the straps holding the tank and unhook them from their brackets.
  2.  
  3. Lower the tank and unhook the vent hose in the sending unit.
  4.  
  5. Remove the fuel tank.
  6.  

To install:
  1. Raise and support the tank. Connect the vent hose and the sending unit wire. Connect and tighten the tank straps.
  2.  
  3. Connect the sending unit wires.
  4.  
  5. Connect the hoses to the tank.
  6.  
  7. Fill the tank and connect the negative battery cable.
  8.  

Dasher and Quantum
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the trunk floor mat.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Disconnect and label the fuel and overflow lines.
  8.  
  9. Disconnect the electrical plugs from the fuel tank gauge sending unit.
  10.  
  11. Detach the vent line from the tank.
  12.  
  13. Remove all the retaining bolts from the trunk floor.
  14.  
  15. Detach the filler tube from the tank filler neck and lower the tank.
  16.  

To install:
  1. Raise and support the tank. Connect the filler tube to the filler neck.
  2.  
  3. Install the trunk floor retaining bolts.
  4.  
  5. Connect the vent line to the tank.
  6.  
  7. Connect the fuel tank gauge sending unit wiring.
  8.  
  9. Connect the fuel lines. Use new clamps.
  10.  
  11. Install the trunk floor mat.
  12.  
  13. Fill the tank and connect the negative battery cable.
  14.  
  15. Reseal the edge of the lower trunk floor to prevent leaks.
  16.  

Fox
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the luggage compartment cover.
  4.  
  5. Remove the access cover to the fuel gauge sending unit.
  6.  
  7. Disconnect the supply line to the main fuel pump.
  8.  
  9. Disconnect the return line to the fuel tank.
  10.  
  11. Unplug the fuel gauge and transfer pump connectors.
  12.  
  13. Using VW tool US 2021A or equivalent spanner wrench, unscrew the fuel gauge sending unit from the tank.
  14.  
  15. Siphon the fuel from the fuel gauge sending unit opening.
  16.  
  17. Raise the rear of the vehicle and support safely.
  18.  
  19. Place a support or stand under the fuel tank.
  20.  
  21. Remove the clamp that connects the filler pipe to the tank.
  22.  
  23. Remove the fuel tank strap nuts.
  24.  
  25. Work the filler pipe hose from the tank.
  26.  
  27. Disconnect the breather hoses and lower the tank.
  28.  

To install:
  1. Raise and support the tank, while connecting the breather hoses. Use new hose clamps as required.
  2.  
  3. Connect the filler pipe hose to the tank.
  4.  
  5. Lower the vehicle.
  6.  
  7. Screw the fuel gauge sending unit into the tank.
  8.  
  9. Plug in the fuel gauge and transfer pump connectors.
  10.  
  11. Connect the fuel tank return and fuel pump supply lines.
  12.  
  13. Install the fuel gauge sending unit access cover.
  14.  
  15. Install the luggage compartment cover.
  16.  
  17. Fill the tank and connect the negative battery cable.
  18.  

1985-89 Scirocco and Cabriolet
  1. Disconnect the negative battery cable and drain the fuel tank.
  2.  
  3. Remove the rear right wheel housing cover.
  4.  
  5. Disconnect the large breather hose from the filler neck.
  6.  
  7. Pull the gravity valve down leaving the hoses connected.
  8.  
  9. Unbolt the fuel pump bracket from the body and lower the pump.
  10.  
  11. Remove the fuel tank screw.
  12.  
  13. Disconnect the fuel pump hose and pull the blue hose from the return line.
  14.  
  15. Disconnect the brake hoses from both sides of the rear axle and plug them.
  16.  
  17. Disconnect the rear axle from both sides of the body and allow it to swing down and rest on the handbrake cable guides.
  18.  
  19. Unhook the rear muffler support lugs.
  20.  
  21. Disconnect the filler hose from the tank.
  22.  
  23. Support the tank, remove the tank fasteners and lower the tank enough to disconnect the fuel gauge sending unit wires and breather hoses.
  24.  
  25. Remove the fuel tank.
  26.  

To install:

If installing a new or used tank, make note of where the old foam strips were installed, and install new foam strips on the replacement tank in the same locations.

  1. Raise and support tank. Connect the small breather hoses and fuel gauge sending unit wires. Install the tank fasteners.
  2.  

When connecting the breather hoses, position the hose clips so that they do not make contact with the body.

  1. Connect the filler hose to the tank and connect the rear muffler support lugs.
  2.  
  3. Raise the rear axle off the handbrake cable guides and install.
  4.  
  5. Connect the brake hoses and bleed the brakes.
  6.  
  7. Connect the return line and fuel pump hose.
  8.  
  9. Install the fuel tank screw.
  10.  
  11. Raise the fuel pump and attach the fuel pump bracket to the body.
  12.  
  13. Put the gravity valve back into its original (raised) position.
  14.  
  15. Connect the large breather hose to the filler neck.
  16.  

When connecting the breather hose, position the hose clip so that it does not make contact with the body.

  1. Install the right rear wheel housing cover.
  2.  
  3. Fill the tank and connect the negative battery cable.
  4.  

 
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