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Crash fuel shut-off > < Removing and installing fuel gauge senderG

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
–  Note safety precautions before beginning work → Chapter.
–  Open fuel tank filler flap.
–  First check whether a coded radio is fitted. If so, obtain anti-theft coding.
–  With ignition switched off, disconnect earth strap from battery.
–  Remove rear right wheel housing liner → General body repairs, exterior; Rep. gr.66.
–  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 bolt.
–  Fold rear bench seat forwards.
–  Remove cover plate from fuel gauge sender and disconnect connector.
–  Remove covers under fuel tank.
–  Remove rear axle: → Running gear, axles, steering, front and four-wheel drive; Rep. gr.42
  WARNING
Fuel supply lines are 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.
  W00-0120
–  Disconnect return line -2- (blue), supply line -1- (black) and breather line -3- (white) at connecting point.
  Note
To do this, press down buttons on hose couplings -arrows-.
–  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. When installing, note the following:
t  Install breather and fuel hoses free of kinks.
t  Route fuel hoses without kinking.
t  Ensure that fuel hose connections are tight.
t  Secure fuel hoses with spring-type clips.
t  Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).
  Note
After installing fuel tank, check that the supply, return and breather lines are still clipped onto the fuel tank.
  A20-0097

Crash fuel shut-off > < Removing and installing fuel gauge senderG