Volkswagen Golf Variant / Jetta. Manual - part 414

 

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Volkswagen Golf Variant / Jetta. Manual - part 414

 

 

bracket.

– Remove the bench seat. Refer to ⇒  Body Interior; Rep. Gr. 

72 ; Rear Seats; Rear Bench Seat, Removing and Installing .

– Unclip the cover -1- for the fuel delivery unit. The arrow -2-

points in the direction of travel.

– Disconnect -1- from the fuel delivery unit flange.
– Remove the center muffler and exhaust pipe. Refer to

⇒ “1.7 Overview - Muffler”, page 381

 .

Note

The front and rear muffler may need to be removed beforehand.

Refer to

⇒ “1.8 Exhaust System, Disconnecting and Connecting”,

page 384

 .

Continuation for All Vehicles

DANGER!

♦ The fuel supply line is under pressure. Always wear pro‐

tective eyewear and protective clothing to prevent injuries

and contact with skin.

♦ Wrap a cloth around the wiring connections before loos‐

ening hose connections. Then release pressure by care‐

fully pulling off the line.

4. Fuel Supply System Components    

239

-2- between the fuel tank and the assembly.

Note

Press the locking ring to release the fuel lines.

– Seal the lines so that no dirt can enter the fuel system.

Note

A second technician is required for the remainder of the proce‐

dure to help support the fuel tank.

– Remove the mounting strap and bolts -arrows-. Support the

fuel tank using the Engine and Gearbox Jack - VAS6931-

when doing this.

– Slowly lower fuel tank.

Note

The fuel filler neck must be “guided out” between the body and

rear axle. To do so, lift the fuel tank down from the Engine and

Gearbox Jack - VAS6931- with the help of a second technician.

Installing:

240

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

Engine and Gearbox Jack - VAS6931- .

– Lift the fuel tank slowly up to the installation position and se‐

cure it with new bolts -arrows-.

• Tightening specification -item 7- 

⇒ Item 7 (page 231)

 /

-item 8- 

⇒ Item 8 (page 233)

 .

Further installation is the reverse order of removal. Note the fol‐

lowing:
• Tightening Specifications: Refer to

⇒ “4.2 Overview - Fuel Tank, All Vehicles Except Jetta from

MY 2011”, page 231

 , Overview - Fuel Tank - All Vehicles Ex‐

cept Jetta from MY 2011

• Tightening Specifications: Refer to

⇒ “4.3 Overview - Fuel Tank, Jetta from MY 2011 Only”, page

233

 , Overview - Fuel Tank - Jetta from MY 2011 Only

• Route the fuel lines without kinks.
• Do not interchange supply and return line (return line blue,

supply line black).

• Make sure the line connections are secure.
• Check the fuel tank/body ground connection on the filler neck

for secure fit -item 3- 

⇒ Item 3 (page 231)

 / -item 3-

⇒ Item 3 (page 233)

 .

• Make sure the fuel lines are still attached to the fuel tank after

installing the fuel tank.

– Observe the notes after connecting the Battery - A- . Refer to

⇒  Electrical Equipment; Rep. Gr.  27 ; Battery; Battery, Dis‐

connecting and Connecting .

4.6

Fuel Delivery Unit, Removing and In‐

stalling

DANGER!

♦ Observe safety precautions when working on fuel supply.

Refer to

⇒ “1 Safety Precautions when Working on Fuel Supply

System”, page 223

 .

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 224

 .

Always pay attention to these instructions before and during

work.

Special tools and workshop equipment required
♦ Wrench - Fuel Sending Unit - T10202-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
Removing:
Conditions
• Fuel tank may be a maximum of 

1

/2 full.

4. Fuel Supply System Components    

241

If necessary, empty the fuel tank using the Fuel Extraction Unit -

VAG5190- . Refer to 

⇒ “4.4 Fuel Tank, Draining”, page 235

 .

Procedure

Caution

Electronic components could be destroyed when the Battery -

A- is disconnected:

♦ Complete the steps for disconnecting the Battery - A- .

– When the ignition is switched off, disconnect the ground cable

-arrow- from the Battery - A- . Refer to ⇒  Electrical Equipment;

Rep. Gr.  27 ; Battery; Battery, Disconnecting and Connecting .

– Remove the bench seat. Refer to ⇒  Body Interior; Rep. Gr. 

72 ; Rear Seats; Rear Bench Seat, Removing and Installing .

– Unclip the cover -1- for the fuel delivery unit. The arrow -2-

points in the direction of travel.

DANGER!

♦ The fuel supply line is under pressure. Always wear pro‐

tective eyewear and protective clothing to prevent injuries

and contact with skin.

♦ Wrap a cloth around the wiring connections before loos‐

ening hose connections. Then release pressure by care‐

fully pulling off the line.

– Disconnect -1-, the black supply line -2- and the blue return

line -3-.

Note

Press the locking ring to release the fuel lines.

– Seal the lines so that no dirt can enter the fuel system.

242

 

 

 

 

 

 

 

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