volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Removing and installing fuel delivery unit > < Removing and installing fuel cooler

Golf Mk4

Removing and installing fuel tank
Removing and installing fuel tank
Special tools and workshop equipment required
   
t  Torque wrench -V.A.G 1331-
  W00-0427
t  Engine and gearbox jack -V.A.G 1383 A-
Removing
Observe safety precautions → Chapter.
Observe rules for cleanliness → Chapter.
–  First check whether a coded radio is fitted. If so, obtain anti-theft coding.
–  Open fuel tank filler flap.
–  With ignition switched off, disconnect earth strap from battery.
–  Remove rear axle → Rep. Gr.42.
–  Remove rear right wheel housing liner → Rep. Gr.68.
Front-wheel drive vehicles
  W00-0120
–  Remove fuel tank cover.
Continuation for all vehicles
–  Drain fuel tank and clean fuel filler neck and surrounding area.
–  Unscrew securing bolt and remove tank flap unit with rubber cup.
–  Remove filler neck securing bolts.
–  Fold rear seat bench forwards.
–  Remove cover plate and pull connector off flange.
  A20-0090
–  Separate fuel supply and return lines on front right of fuel tank.
  WARNING
t  The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
t  The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!
t  Wear eye and hand protection when performing any type of repair work on the fuel system!
  Note
To do this, press down buttons on hose couplings -arrows-.
Vehicles with four-wheel drive
  A20-0092
–  Remove securing nuts/bolts -arrows-.
Continuation for all vehicles
–  Remove securing straps. When doing this, support fuel tank with engine and gearbox jack -V.A.G 1383 A-.
–  Lower fuel tank.
Installing
Installation is carried out in the reverse order of removal. When doing this, note the following:
t  Route breather and fuel hoses free of kinks.
t  Ensure that fuel hoses are tight.
t  Do not interchange supply line and return line (return line blue or with blue marking, supply line black).
t  Clip supply and return lines onto fuel tank.
  Note
After installing fuel tank, check that the supply, return and breather pipes are still clipped onto the fuel tank.
  N20-0276

Removing and installing fuel delivery unit > < Removing and installing fuel cooler