Volkswagen Workshop Service and Repair Manuals

(40 litre tank)

Part I

• T-piece
• ◆ 08.78 ä with restrictor in connection for return pipe
• Return pipe
• ◆ With restrictor ä 07.78 =>Fig. 4
• ◆ Return pipe connection with 1B3 carburettor 04.80 onwards =>Fig. 5
• Fuel filter
• ◆ Arrow points in direction of flow (towards the fuel pump)
• To carburettor
• Suction pipe
• ◆ Black
• Return pipe
• ◆ Blue

• Fuel gauge sender
• ◆ Removing =>Fig. 6
• ◆ Installing =>Fig. 7
• O-ring
• ◆ Renew
• ◆ Rub with graphite powder before installing
• Tensioning strap
• ◆ Only use rubber packing
• 25 Nm
• Rubber packing
• Fuel tank
• ◆ Removing
• ◆ Always apply long-term
  underseal D 35
• ◆ 08.79 ä modified fuel tanks with modified breather system
• ◆ 01.84 ä Golf Convertertible, Scirocco with enlarged fuel tank (55 l), not for subsequent installation

• Sealing flange
• O-ring
• ◆ Renew
• 20 Nm
• Fuel pump
• ◆ 0.2...0.25 bar
• Gasket
• ◆ Renew
• Fuel pump strainer
• Fuel pump cover
• ◆ Depression in cover must engage in recess in pump housing

Part II

• Small breather pipes
• ◆ ä 07.79
• Small breather pipe
• ◆ 08.79 ä
• Large breather pipe
• ◆ 08.79 ä
• Small breather pipe
• ◆ into the open
• Gravity valve
• ◆ 08.79 ä
• ◆ Checking: modified fuel tank with modified breather system
• ◆ Position => Fig.8
• Bracket
• Cap
• ◆ Up to chassis no. 178 3 187 615/538 2 040 975 - with ventilation
• ◆ As of chassis no. 178 3 187 616/538 2 040 976 - no ventilation

• Gasket
• ◆ Renew if damaged
• Filler neck
• ◆ For cat. and unleaded with constriction and spring-loaded flap
• Large breather pipe
• ◆ ä 07.79
• Drain hose
• Connecting hose
• Non-return valve
• ◆ Checking => Fig. 9
• Drain hose

→ Fig.1     Fuel reservoir (plastic)

Vehicles with 1B3 carburettor 06.80 ä are fitted with a reservoir (plastic).

Connections:

K - Fuel pump

R - Return line

V - Carburettor

→ Fig.2     Fuel reservoir

Vehicles with 2E2 carburettor are fitted with a reservoir (sheet steel).

Connections:

A - Carburettor (no marking)

B - Fuel pump (arrow)

C - Return line (R)

→ Fig.3     Fuel filter in delivery tubing

Vehicles with 2B5 carburettor are provited with an additional filter in the fuel line between fuel pump and carburettor. If necessary, the filter is to be replaced by a T piece.

→ Fig.4     Fuel return line

08.75 äall vehicles feature a return line.

ä07.78: Return line with restrictor -arrow-

08.78 ä : Restrictor in T piece

→ Fig.5     Return line connection with 1B3 carburettor

04.80 ä return line connected directly to the float chamber -arrow-. Restrictor is located in connection piece.

Note:

Do not interchange supply and return lines.

→ Fig.6     Removing fuel gauge sender

• ‒ To do so, remove rear seat bench and cover.
  Release bayonet catch by turning sender.

Note:

On vehicles ▸01.76 the sender is installed in the fuel tank on the right side (accessible from underside of vehicle).

→ Fig.7     Installation position of fuel gauge sender

Electrical connection must coincide with the broken line. Arrow points in direction of travel.

→ Fig.8     Installation position of gravity valve

•      A -     Valve must be installed vertically with "Canister" connection upwards
•      B -     Small breather pipe to fuel tank
•      C -     Drain hose (to open air)
•      D -     Large breather pipe

→ Fig.9     Testing check valve

03.77 ä there is a check valve in the fuel tank inlet connection.

When repairing the fuel tank, ensure that valve moves easily and that it is installed correctly (hanging).

Rules for cleanliness

Pay attention to the following "5 rules" for cleanliness when working on the fuel system:

• ◆ Thoroughly clean all points of connection and the adjacent areas before disconnecting.
• ◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths.
• ◆ Components that have been opened must be carefully covered or sealed if the repair cannot be carried out immediately.
• ◆ Only install clean components:
  Only unpack replacement parts immediately prior to installation.
  Never user parts that have been stored loose (for instance in toolboxes).
• ◆ When the system is open:
  Do not work with compressed air if this can be avoided. Do not move the vehicle unless absolutely necessary.

Removing and installing fuel tank

(40 litre fuel tank)

Removing

Note rules for cleanliness => page 20-12 .

• ‒ Detach earth strap at battery with ignition switched off.

Note:

If applicable, first interrogate the radio antitheft coding.

• ‒ Empty tank.
• ‒ Pull large breather pipe off filler neck.
• ‒ Pull off gravity valve downwards (lines remain connected).

• ‒ → Detach brake hoses on left and right at rear axle -black arrow-.
• ‒ Detach rear axle from body on both sides -white arrows-, swing it down and let it hang on the handbrake guide cables.

• ‒ Unhook support loops at exhaust system.
• ‒ Pull connecting hose off tank.
• ‒ Detach straps from body and lower tank.
• ‒ Pull connector as well as supply and return line off flange.
• ‒ Pull off breather hoses and take tank out.

Installing

• ‒ Installation is performed in reverse order.

=> Bleeding brake system; Repair Group 47;

Note:

• ◆ On connecting large and small breather pipe, turn clamps such that they have no contact with body.
• ◆ Vehicles with a catalyst which run on unleaded fuel have a constriction in the filler neck and a spring-loaded flap.