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

Golf Mk4

Removing and installing fuel tank
Removing and installing fuel tank
Special tools and workshop equipment required
   
t  Fuel extractor -VAS 5190-
  W00-1107
t  Engine and gearbox jack -V.A.G 1383 A-
t  Torque wrench -V.A.G 1331-
Removing
–  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.
–  Open fuel tank filler flap.
  W00-0120
–  Push suction hose -arrow- of fuel extractor -VAS 5190- about 100-120 cm into fuel filler neck and extract fuel.
–  Unscrew securing bolt and remove tank flap unit with rubber cup.
–  Remove filler neck securing bolts.
–  Remove rear right wheel housing liner → General body repairs, exterior; Rep. gr.66.
–  Clean area around fuel filler neck.
–  Fold rear bench seat forwards.
–  Remove cover on right and left under rear seat.
–  Remove heat shield 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.
  N20-0538
–  Disconnect return line -2- (blue), supply line -1- (black) and breather line -3- (white) at connecting point.
  Note
Press buttons on hose couplings to do this.
  A20-0097
–  Unscrew securing bolts/nuts -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  Secure fuel hoses with spring-type clips.
t  Route fuel hoses without kinking.
t  Ensure that fuel hose connections are tight.
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.
  N20-0276

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