Volkswagen Golf / Golf Plus. Manual - part 323

 

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Volkswagen Golf / Golf Plus. Manual - part 323

 

 

– 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

2) Low-pressure section

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

tions”.

4.2.2

Emptying fuel tank if it is more than 

3

/4

full

Caution

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

part of the body.

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

130

     Rep. Gr.20 - Fuel supply system

 

– 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 131

4.2.3

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 .

– Remove cover from fuel delivery unit.

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.

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

4. Fuel tank, vehicles with four-wheel drive    

131

 

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.

4.3

Removing and installing fuel tank

Special tools and workshop equipment required
♦ Torque wrench (5…50 Nm) -V.A.G 1331-

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

Remove fuel tank 

⇒ page 132

 .

4.3.1

Removing fuel tank

– Note safety precautions before beginning work 

⇒ page 114

 .

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

132

     Rep. Gr.20 - Fuel supply system

 

these vehicles it is sufficient to remove the rear propshaft. Vehi‐

cles from 06/2007 are fitted with a single part propshaft. For these

vehicles the complete propshaft must be removed.

Special tools and workshop equipment required
♦ Torque wrench (5…50 Nm) -V.A.G 1331-

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

– First check whether a coded radio is fitted. If so, obtain anti-

theft coding.

Before disconnecting battery, open fuel tank flap and if necessary

remove wheel lock adapter from luggage compartment.
– With the ignition switched off, disconnect battery earth strap.

⇒  Electrical system; Rep. Gr.  27 ; Disconnecting and con‐

necting batteries .

If necessary, drain fuel tank using fuel extractor -VAS 5190- .

⇒ page 128

– Unbolt rear right wheel.
– Remove rear right wheel housing liner. ⇒  General body re‐

pairs, exterior; Rep. Gr.  66 ; Removing and installing wheel

housing liner; Rear wheel housing liner .

– Unscrew securing bolts and remove tank flap unit. ⇒  General

body repairs, exterior; Rep. Gr.  55 ; Fuel flap unit

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

4. Fuel tank, vehicles with four-wheel drive    

133

 

 

 

 

 

 

 

 

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