volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Vehicles with four-wheel drive > < Vehicles with front-wheel drive ? 08.00

Golf Mk4

Vehicles with front-wheel drive 09.00 ▸
Vehicles with front-wheel drive 09.00 ►
  Note
Ensure, on completion of all work on the fuel delivery unit and fuel gauge that the fuel supply and fuel return hoses do not touch the fuel tank (transfer of pumping noises).
   
1 - Cap
q   With retainer clip.
2 - Seal
q   Renew if damaged.
3 - Securing bolt
4 - Tank flap unit
q   With rubber cup.
5 - Earth connection
q   Check for secure seating.
6 - O-ring
q   Renew if damaged.
7 - Breather valve
q   To remove valve unclip sideways out of support.
q   Unscrew cap before installing
q   Checking → Fig..
8 - 10 Nm
9 - Breather line
q   Clipped onto top of fuel tank.
q   Check for secure seating.
q   Secure with spring-type clips.
10 - Clamping washer
11 - Heat shield
q   For fuel tank.
12 - Fuel tank cover
13 - 25 Nm
14 - Securing strap
q   Note differing lengths.
15 - Fuel tank
q   When removing, support using engine and gearbox jack -V.A.G 1383 A-.
q   Removing and installing → Chapter
16 - Seal
q   Renew if damaged.
q   When installing, insert seal dry into fuel tank opening.
q   Moisten with fuel only when installing flange.
17 - Fuel delivery unit
q   Note installation position of flange on fuel tank → Fig..
q   Removing and installing → Chapter
q   Checking fuel pump → Chapter
q   With fuel gauge sender -G-
q   Removing and installing fuel gauge sender → Chapter
q   Clean strainer if soiled.
18 - Union nut
q   Remove and install using union nut tool -3217-.
19 - Supply line
q   To fuel filter → Chapter.
q   Black.
q   Clipped onto fuel tank.
q   Check for secure seating.
q   To pull off flange, press release button on connecting piece.
20 - Return line
q   From fuel cooler
q   On connection -R-
q   Blue or with blue marking.
q   Clipped onto fuel tank.
q   Check for secure seating.
q   To pull off flange, press release button on connecting piece.
21 - Gravity/overflow valve
q   To remove valve unclip upwards out of support.
q   Check valve for through-flow; valve vertical: open, valve tilted 45°: closed
22 - Angled piece

   
Installation position of fuel delivery unit
Marking on flange must align with the marking on fuel tank -arrows-.
Blue or blue marked return line -1- to connection marked -R-.
Black supply line -2- to connection marked -V-.
  Note
After installing fuel delivery unit flange, check that supply, return and breather lines are still clipped onto fuel tank.
  A20-0096
Checking vent valve
Lever in rest position: closed
Lever pushed in direction of arrow: open
  Note
Before installing vent valve remove fuel tank cap.
  V20-1040

Vehicles with four-wheel drive > < Vehicles with front-wheel drive ? 08.00