volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Checking fuel pump > < Removing and installing fuel pump

Golf Mk4

Vehicles with four-wheel drive
Vehicles with four-wheel drive
Special tools and workshop equipment required
   
t  Union nut tool -3217-
Removing
Observe safety precautions → Chapter.
Observe rules for cleanliness → Chapter.
–  First check whether a coded radio is fitted. If so, obtain anti-theft coding.
–  With the ignition switched off, disconnect battery earth strap.
–  Fold rear seat bench forwards.
–  Remove cover under bench seat.
–  Pull 4-pin connector as well as supply and return pipes off flange.
  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
Press buttons on hose couplings to do this.
  W00-0291
–  Unscrew union nut with union nut tool -3217-.
–  Pull supply hose off fuel pump → Item.
  Note
Press button on hose coupling to do this.
–  Separate 2-pin connector → Item.
–  Unclip return hose bracket out of fuel pump → Item.
–  Pull fuel pump and seal out of the opening in fuel tank.
  Note
If the fuel pump is to be renewed then drain old fuel pump before disposal.
Installing
–  Installation of the fuel pump is carried out in the reverse order of removal.
  Note
t  Do not bend fuel sender when installing.
t  Insert seal for fuel pump or sender 2 dry into fuel tank opening.
t  Moisten seal with fuel only when installing fuel pump or sender 2.
t  Ensure that fuel hoses are tight.
  A20-0106
t  Note Installation position of fuel pump flange: mark on flange must align with mark on fuel tank -arrows-.
t  After installing fuel pump flange, check that supply line -2- and return line -1- are still clipped onto fuel tank.
  N20-0269

Checking fuel pump > < Removing and installing fuel pump