Fuel tank modifications
In January 1976, the location of the fuel level sensor was changed - the sensor was moved from the right side to the upper surface of the tank. In August 1979, thicker tank ventilation tubes were installed instead of thin ones.
The top-mounted fuel level sensor is accessible through a hole in the floor of the vehicle under the rear seat. The sensor is secured to the tank with a bayonet retaining ring that is easy to remove. When installing the sensor, ensure that the electrical connector is facing forward, or slightly to the left on fuel-injected models.
On injection models, a ventilation valve is built into the tank ventilation tube. On cars manufactured before August 1979, the valve has two branches, and on later models, a third one is added - an atmospheric branch. Since August 1979, a safety valve is installed instead of the ventilation valve, which closes under the force of gravity. Since that time, safety valves have also been installed on carburetor models. Safety valves come in different types, and the valve can only be replaced with a valve of the same type. Valves are distinguished by color markings. The safety valve must be installed vertically, with the "CANISTER" marking facing up.
The fuel cap on cars manufactured before August 1979 had a vent hole, while on later models the vent hole in the cap is missing. The caps are distinguished by the inscription on the back: the cap without a vent hole has the inscription "ohne Luftung", and a cork with ventilation - "mit Luftung".
Early fuel injected models had threaded fuel filler caps, but these were replaced by bayonet-type ones, the same as those used on carburettor models from August 1979.
Removal and installation the fuel tank - Golf/Jetta models
1. Disconnect the ground wire from the battery.
2. Pump out the remaining fuel from the tank through the filler neck.
3. If the fuel level sensor is located on top, remove the rear seat and remove the cover to gain access to the sensor. Disconnect the electrical connector from the sensor and (on carburetor models) both fuel pipes. Mark one of the pipes with chalk to ensure proper installation during assembly.
4. If the fuel level sensor is installed on the side of the tank, it can be accessed from under the vehicle.
5. On injection models, disconnect the wires and tubes from the fuel pump and remove the fuel pump. Disconnect the fuel supply and return tubes from the fuel tank.
6. Loosen the rear wheel mounting bolts, lift and place the rear of the vehicle on supports (see chapter "Basic rules for carrying out work"). Remove the rear wheels.
7. To remove the fuel tank, you need to separate the rear axle from the body. Disconnect the brake hoses from the rear axle on both sides (plug the pipes and hoses to prevent brake fluid from leaking out), disconnect the rear axle mounts from the body, turn the axle down and leave it hanging on the handbrake cable casings.
8. Unhook the exhaust system hangers.
9. Disconnect the filler hose from the fuel tank and close the opening in the tank.
10. Disconnect the two fastening straps from the body and lower the tank.
11. Remove the vent tubes from the tank connections, then remove the tank from under the vehicle.
Installation is carried out in the reverse order of removal. Install rubber gaskets between the fuel tank and the fastening bands. Use new clamps to secure the hoses.
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