Volkswagen Golf / Golf Plus. Manual - part 320

 

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Volkswagen Golf / Golf Plus. Manual - part 320

 

 

♦ Torque wrench (40…200 Nm) -V.A.G 1332-
– Note safety precautions before beginning work 

⇒ page 114

 .

Emptying fuel tank, bleeding fuel system when fuel pump is intact

⇒ page 118

 .

Emptying fuel tank if more than 

3

/4 full 

⇒ page 120

Emptying fuel tank if less than 

3

/4 full 

⇒ page 120

3.2.1

Emptying fuel tank, bleeding fuel system

when fuel pump is intact

Special tools and workshop equipment required
♦ Diagnostic tester
♦ Fuel extractor -VAS 5190-
♦ Adapter for fuel extraction -VAS 5190 /3 -

WARNING

Fuel supply line is pressurised. Wear eye protection and pro‐

tective clothing to avoid possible injury and skin contact. Before

loosening hose connections, wrap a cloth around the connec‐

tion. Then release pressure by carefully pulling hose off con‐

nection.

Note

Press in securing ring to release fuel lines.

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

118

     Rep. Gr.20 - Fuel supply system

 

tractor -VAS 5190 /3 - to fuel supply line.

– Connect a diagnostic tester.

Note

The fuel pump is being activated when engine is not running.

– Switch on ignition.
– Remove filler cap from fuel tank filler neck.
– Perform the function “Emptying fuel system” in “guided func‐

tions”.

If the fuel tank is emptied, “stop” the function to prevent the fuel

pump from running “dry”.
– Operate shut-off tap on fuel extractor -VAS 5190- , until the

fuel tank is emptied.

Bleeding fuel system

1) Low-pressure section

• Fuel tank filled.
– Connect a diagnostic tester.
– Perform the function “Bleeding fuel system” in “guided func‐

tions”.

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

3. Fuel tank, vehicles with front-wheel drive    

119

 

3

/4

full

Caution

Secure earth wire of fuel extractor -VAS 5190- to a bare metal

part of the body.

– Remove cotter -2- from shaft -1- of fuel extractor -VAS 5190- .
– At distance -a- = 1180 mm from end, mark extraction hose with

insulating tape -arrow-.

– Remove filler cap from fuel tank filler neck.
– Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel

filler neck.

– Push extraction hose into fuel tank until marking on hose

-arrow- coincides with shaft end.

Note

A ball valve -2- is located at the bottom of the filler neck in the fuel

tank -1-; it must not be damaged by the extraction hose -3-.

Therefore push hose into filler neck only as far as marking

-arrow-.

– Empty fuel tank as far as possible.
– Carefully pull out extraction hose.

Note

When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.

If the fuel tank has to be drained fully, proceed as follows:

⇒ page 120

3.2.3

Emptying fuel tank if it is less than 

3

/4 full

– Remove bench seat ⇒  General body repairs, interior; Rep.

Gr.  72 ; Rear seats; Removing and installing bench seat .

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

120

     Rep. Gr.20 - Fuel supply system

 

Fuel supply line is pressurised. Wear eye protection and pro‐

tective clothing to avoid possible injury and skin contact. Before

loosening hose connections, wrap a cloth around the connec‐

tion. Then release pressure by carefully pulling hose off con‐

nection.

– Pull connector and fuel lines off flange.

Note

Press buttons on hose couplings to do this.

– Open locking ring using fuel tank sender wrench -T10202- .
– Lift sender flange.
– Insert extraction hose of fuel extractor -VAS 5190- as deeply

as possible into fuel tank and extract fuel.

If fuel tank needed only to be emptied, reinstall sender flange.

3.3

Removing and installing fuel tank

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

♦ Engine and gearbox jack -V.A.G 1383/A-

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

3. Fuel tank, vehicles with front-wheel drive    

121

 

 

 

 

 

 

 

 

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