Volkswagen Golf/Jetta/Cabriole 1990-1999

Fuel Tank Assembly

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REMOVAL & INSTALLATION



Always ground yourself to the vehicle's chassis to prevent sparks while working on or around the fuel tank.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the access panel under the rear seat or in the luggage compartment.
  4.  
  5. Disconnect the gauge sending unit wiring and hoses.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Drain the fuel tank into an approved container.
  10.  
  11. On Cabriolet models, remove the right rear inner fender and disconnect the breather hose from the filler. Remove, but do not disconnect the gravity valve.
  12.  
  13. Detach the fuel pump bracket from the body.
  14.  
  15. Lower the pump enough to disconnect the fuel hoses from the tank.
  16.  
  17. On Cabriolet models, the rear axle must be dropped out of the way as follows:
    1. Disconnect the brake hydraulic hoses at both sides of the rear axle.
    2.  
    3. Detach the rear axle from the body on both sides and let it hang on the parking brake cables.
    4.  

  18.  
  19. Unhook the muffler supports and pull the large hose from the filler neck.
  20.  
  21. Support the tank, loosen the straps and carefully lower the tank out of the vehicle.
  22.  

To install:

  1. If a new tank is being installed, glue new foam strips to the tank in the same location as the old ones.
  2.  
  3. Position the tank and secure it with the straps.
  4.  
  5. Connect the wiring and hoses to the sending unit.
  6.  
  7. Attach the fuel pump bracket to the body.
  8.  
  9. On Cabriolet models, install the rear axle, connect the hydraulic lines and bleed the brakes.
  10.  
  11. Install the access panel once all electrical connections have been made.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Fill the tank with fuel and check for leaks.
  16.  

 
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