Volkswagen Golf / Golf Plus. Manual - part 324

 

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Volkswagen Golf / Golf Plus. Manual - part 324

 

 

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

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

– Remove covers and separate electrical connectors -arrows-.
– Remove centre and rear silencers.

– Secure exhaust system to underbody using wire.
– Remove rear propshaft ⇒  Manual gearbox; Rep. Gr.  39 ; Final

drive, differential, differential lock

Vehicles from 06/2007 (single part propshaft):
– Remove complete exhaust system 

⇒ page 186

 .

– Remove complete propshaft ⇒  Propshaft and rear final drive;

Rep. Gr.  39 ; Repairing propshaft - Golf .

Continuation for all vehicles:

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.

– Pull off adapter cable on four-wheel drive control unit -J492- .

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

134

     Rep. Gr.20 - Fuel supply system

 

– Slowly lower fuel tank.

Note

The filler neck must be “guided out” between body and rear axle.

To do this, take the fuel tank off engine and gearbox jack -V.A.G

1383 A- with the assistance of a 2nd mechanic.

4.3.2

Installing fuel tank

– Clip in cable for four-wheel drive control unit -J492- on fuel

tank.

– With the aid of a 2nd mechanic, guide the filler neck in between

rear axle and body. Then place the fuel tank on the engine and

gearbox jack -V.A.G 1383 A- .

– Raise the fuel tank slowly up to the installation position and

secure -arrows-.

– Fit adapter cable on four-wheel drive control unit -J492- .
The remaining installation steps are carried out in the reverse se‐

quence. In the process, note the following:
♦ Install breather and fuel lines free of kinks.
♦ Do not interchange supply line and return line (return line blue

or with blue marking, supply line black).

♦ Ensure that line connections are firmly seated.
♦ Check earth connection on fuel tank and body to filler neck.

4.4

Removing and installing fuel gauge

sender 2 -G169-

• The fuel tank should be no more than half full

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

4. Fuel tank, vehicles with four-wheel drive    

135

 

Ensure that the fuel gauge sender is not bent.

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

⇒ page 128

Note safety precautions before starting work 

⇒ page 114

 .

Observe rules for cleanliness 

⇒ page 115

 .

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

theft coding.

– With the ignition switched off, disconnect battery earth strap.

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

necting batteries .

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

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

– Remove left cover (as seen facing direction of normal travel)

from fuel gauge sender 2 -G169- .

– Disconnect electrical connectors.
– Open locking ring using wrench -T10202- .

– Pull fuel gauge sender 2 -G169- upwards slightly and unclip it

from the suction-jet pump.

Installing:

Caution

When installing do not bend fuel gauge sender 2 -G169- float

arm.

– Place fuel gauge sender 2 -G169- in fuel tank.

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

136

     Rep. Gr.20 - Fuel supply system

 

– Place a new flange seal dry into opening in fuel tank and mois‐

ten inside (contact to flange) only with fuel.

– Note installation position of fuel gauge sender 2 -G169-

⇒ page 128

– Check for correct position of seal.

– Tighten locking ring using wrench -T10202- . Specified torque:

110 Nm.

– Fit connectors.
– Install cover.
– Install bench seat. ⇒  General body repairs, interior; Rep. Gr. 

72 ; Rear seat; Removing and installing seat bench .

4.5

Removing and installing suction-jet

pump

Note

On vehicles with four-wheel drive, fuel has to be pumped from

the area of fuel gauge sender 2 -G169- to the fuel delivery unit

by means of a suction jet pump due to the shape of the fuel

tank.

Checking is only necessary when the engine stops due to lack

of fuel, even though the fuel gauge shows that the tank is still

1/4 full.

Procedure
– Remove fuel delivery unit 

⇒ page 123

 .

– Pull return hose of suction-jet pump out of fuel delivery unit

-arrow-.

– Separate quick-release coupling of supply line from suction-

jet pump on Y-piece of fuel delivery unit.

– Remove fuel gauge sender 2 -G169- 

⇒ page 135

 .

– Now the suction-jet pump can be pulled out from side of fuel

gauge sender 2 -G169- (left side of vehicle).

– Check that the fuel lines on suction-jet pump are fitted securely

and are not damaged.

– Additionally check suction-jet pump for possible soiling.

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

4. Fuel tank, vehicles with four-wheel drive    

137

 

 

 

 

 

 

 

 

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