Volkswagen Golf / Golf Plus. Manual - part 319

 

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Volkswagen Golf / Golf Plus. Manual - part 319

 

 

Safety precautions when working on

fuel supply system

WARNING

When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐

tions:

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

vated charcoal filter system, coolant, refrigerant, brake

fluid and vacuum) and electrical wiring in their original po‐

sitions.

♦ Ensure that there is sufficient clearance to all moving or

hot components.

♦ The fuel and the fuel lines in the fuel system can become

very hot (danger of scalding)!

♦ The fuel system is also under pressure! Before opening

the system, place cloths around the connections. Then

carefully loosen connection to release the pressure!

♦ Wear eye and hand protection when performing any type

of repair work on the fuel system!

When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the

following:
♦ Before beginning work, place an extraction hose close to

sender opening in fuel tank to extract escaping fuel fumes and

switch on exhaust extraction system. If no exhaust gas ex‐

traction system is available, a radial fan with a displacement

greater than 15 m

3

/h can be used providing that motor is not

in air flow.

♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

114

     Rep. Gr.20 - Fuel supply system

 

When working on the fuel supply and injection systems, pay care‐

ful attention to the following “6 rules” for cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐

connecting.

♦ Place removed parts on a clean surface and cover. Do not use

fluffy cloths!

♦ Carefully cover opened components or seal if repairs cannot

be carried out immediately.

♦ Install clean components only. Do not remove replacement

parts from packing until immediately before installing. Do not

use parts that have not been stored in their packing (e.g. in

tool boxes etc.).

♦ When system is open: do not work with compressed air if this

can be avoided. Do not move vehicle unless absolutely nec‐

essary.

♦ Also ensure that no diesel fuel runs on to the coolant hoses.

Should this occur, the hoses must be cleaned immediately.

Damaged hoses must be renewed.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2. Rules for cleanliness    

115

 

drive

Observe safety precautions 

⇒ page 114

 .

Observe rules for cleanliness 

⇒ page 115

 .

Assembly overview - fuel tank 

⇒ page 116

 .

Emptying fuel tank 

⇒ page 117

 .

Removing and installing fuel tank 

⇒ page 121

 .

Removing and installing fuel delivery unit 

⇒ page 123

 .

Removing and installing fuel gauge sender 

⇒ page 124

 .

Checking fuel pump 

⇒ page 125

 .

3.1

Assembly overview - fuel tank

1 - Sealing cap
2 - 1.5 Nm
3 - Earth connection

❑ Check for secure seat‐

ing.

4 - 10 Nm
5 - Wiring duct
6 - Fuel tank

❑ When removing, sup‐

port using engine and

gearbox jack -V.A.G

1383/A- .

❑ Removing and installing

⇒ page 121

 .

7 - 25 Nm

❑ To secure the securing

straps for the fuel tank,

only bolts with loose

washers must be used.

If other bolts are used,

the securing straps

could be twisted whilst

tightening. Bolts ⇒  ET‐

KA (electronic parts

catalogue) .

❑ Renew.

8 - Clamping washer
9 - Securing strap

❑ Note installation posi‐

tion.

10 - Heat shield

❑ For fuel tank.

11 - Seal

❑ Renew if damaged.
❑ Moisten with fuel when installing

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

116

     Rep. Gr.20 - Fuel supply system

 

⇒ page 117

 .

❑ Removing and installing 

⇒ page 123

 .

❑ Checking fuel pump 

⇒ page 125

 .

❑ Removing and installing fuel gauge sender 

⇒ page 124

 .

❑ Clean strainer if soiled

13 - Locking ring

❑ Remove and install using fuel tank sender unit tool -T10202- .
❑ Specified torque: 110 Nm.

14 - Supply line

❑ To fuel filter
❑ Clipped onto fuel tank
❑ Check for secure seating.
❑ Black
❑ To pull off flange, press release button on connecting piece.

15 - Return line

❑ From fuel cooler
❑ Blue or with blue marking.
❑ Clipped onto fuel tank
❑ Check for secure seating.
❑ To pull off flange, press release button on connecting piece.

16 - Tank flap unit

❑ Removing and installing ⇒  General body repairs, exterior; Rep. Gr.  55 ; Tank flap unit .

Installation position of fuel delivery unit
Marking -3- on the flange must align with marking on the fuel tank.
Return line blue or with blue marking -1-.
Supply line (black) -2-.

Note

After installing fuel delivery unit flange, check that supply, return

and breather lines are still clipped onto fuel tank.

3.2

Emptying fuel tank

Special tools and workshop equipment required

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

3. Fuel tank, vehicles with front-wheel drive    

117

 

 

 

 

 

 

 

 

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