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Removing and installing fuel delivery unit > < Rules for cleanliness

Golf Mk4

Removing and installing suction-jet pump
Removing and installing suction-jet pump
On vehicles with four-wheel drive, fuel has to be pumped from the area of fuel gauge sender 2 -G169-, → Item, to the fuel delivery unit → Item by means of a suction-jet pump due to the shape of the fuel tank. The suction-jet pump operates on a physical principle. It is powered by an additional connection from the fuel pump via the fuel supply.
  Note
Checking is only necessary if the engine stops due to lack of fuel, even though the fuel gauge shows that the tank is still filled above the reserve level.
Special tools and workshop equipment required
   
t  Union nut tool -3217-
  W00-0291
t  Fuel extractor -VAS 5190-
t  Torque wrench -V.A.G 1332-
Prerequisites
l  Fuel tank must be drained.
l  Both fuel gauge senders have been checked using fault-finding program and are OK: → Current flow diagrams, Electrical fault finding and Fitting locations
Procedure
–  Note safety precautions before beginning work → Chapter.
  Note
Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.
–  With the ignition switched off, disconnect battery earth strap.
–  Remove cover under rear seat.
  WARNING
Fuel system is under pressure! Wear eye protection and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
  W00-1107
–  Unplug 4-pin connector and fuel hoses from fuel delivery unit (right side of vehicle) and remove fuel delivery unit → Chapter.
  A20-0106
–  Unscrew union nut of fuel gauge sender 2 -G169- on left side of vehicle.
–  Lift sender 2 upwards as far as possible.
  N20-0301
–  Cut cable ties at fuel line -arrow- and carefully pry bearing for suction-jet pump apart at sender 2 -direction arrows-.
–  You can now unclip the suction-jet pump with fuel supply and return lines from sender 2 and remove.
–  Check that the fuel lines on suction-jet pump are fitted securely and are not damaged.
–  Additionally check suction-jet pump for possible soiling.
If no fault is found:
–  Install suction-jet pump and sender 2 again in reverse order.
  Note
t  Please note that the seal → Item has to be placed dry in the fuel tank opening before installing the fuel fuel delivery unit or sender 2.
t  Always renew seals if the fuel has caused them to swell.
  N20-0302

Removing and installing fuel delivery unit > < Rules for cleanliness