I installed the fuel filler door lock on my 98 GTI today. Piece of cake.
Many thanks to Rob Heckel for providing the following information:
It was incredibly easy. It truly can be done in 15 minutes.
Just thought I'd give my updates to this procedure:
Tools necessary: phillips head screwdriver
snips (I used my trusty wire cutters)
Swiss Army knife
Parts necessary: valve (comes w/2 mounting screws) 1H0862160A ~$35
adapter (vacuum tubing connector) 1HM862190AC ~$3.00
vacuum tubing - Pep Boys - 4mm vinyl tubing ~$3.00
vinyl/plastic adhesive - Pep Boys ~$4.00
I did not need the drill for installation in my 1998 GTI, as you will see
when you read on.
I got my parts from Devon Hill VW, in Devon, PA. Many thanks to Devon Hill,
they've been very nice to me. I also got some scrap vacuum tubing from the
parts guy, however, I found the VW stuff VERY hard to work with and opted to
go to Pep Boys to get more rubbery tubing. It came in a 6 foot roll, and is
5/32 inch diameter (4mm). While 3 inches may be all you need, I likewise
used approximately 6 inches of tubing. I also left the 2 inch piece of
yellow tubing on the adapter (although I'm not sure that it is necessary).
I did plug the adapter into the valve, and did blow and suck (on the
adapter, sick-o), and low and behold, it worked like a champ. I also
installed mine with the rod extended, although again, I'm not sure that it
matters, but I think it is easier with the rod extended. I actually removed
the valve adapter to do the tubing installation because it was easier to
When I pulled down the carpeting in the hatch, I found the T-shaped vacuum
connector with only 2 sides used, but the third wasn't plugged, it was
crimped. No biggie, I just used my snips to snip off the crimped portion to
ensure airflow. This is where you would have used the drill, thus I didn't
need it. The valve does go between the 2 layers of sheet metal. It's
actually very intuitive, once you look at it. The inbound sheet metal was
all set up to receive the valve, with two notches that the valve slides
into, then you just tighten the screws. For those of you with a Bentley
bible, refer to page 57-13, Fig 23 (although, again, it really is easy to
figure out without the manual just by looking at the car.
I did remove the rubber grommet sleeve in the fuel door area where the
locking rod would go. I also found that the rubber grommet sleeve did not
have a hole for the rod, so I had to poke a whole with my trusty Swiss Army
After sizing everything up, I cut my 6 inch piece of vinyl tubing from the 6
foot roll that I got from Pep Boys.
At this point, I was ready to go. I smeared some of the plastic/vinyl
adhesive on the empty connector of the T-shaped vacuum connector, then slid
on one end of the 6 inch section of vacuum tubing onto the connector.
Then, I smeared some of the plastic/vinyl adhesive on the yellow piece of
tubing on the valve adapter. Then, I slid the other end of the tubing onto
the valve adapter.
Next, I plugged the valve adapter into the valve. Piece of cake.
Finally, I was able to poke the rod through the hole in the fuel filler
area, got the valve in position, and tightened down the mounting screws.
Replace the rubber grommet sleeve in the fuel filler door area. Put all the
carpet back in place, and it's ready to rock. It works just like it should,
locks and unlocks with the car.
I hope this helps others who are equally annoyed at VW removing this feature
from the vehicle.