VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing fuel line for auxiliary/supplementary heater

Removing
–  Observe safety precautions → Chapter.
–  Observe rules for cleanliness → Chapter.
–  Fuel tank must not be more than 3/4 full. This ensures that the fill level is below the flange of the fuel delivery unit.
–  Draining fuel tank → Chapter
–  Remove rear bench seat → General body repairs, interior; Rep. gr.72.
   
–  Unclip cover -1- for flange at retaining tabs -arrows-, using removal wedge -3409-.
 

Removing and installing fuel line for auxiliary/supplementary heater

–  Unclip sealing grommet -1- downwards from cover -2-.
–  Push cover -2- back along wiring harness -3-.
 

Removing and installing fuel line for auxiliary/supplementary heater

Vehicles with front-wheel drive
–  Release and pull off connector -1- on sealing flange.
–  If fitted, detach connector -2- for metering pump -V54- of auxiliary heater on sealing flange and lay connector aside.
 

Removing and installing fuel line for auxiliary/supplementary heater

Vehicles with four-wheel drive:
–  Release and pull off connectors -1- and -2- on sealing flange.
–  If fitted, detach connector -3- for metering pump -V54- of auxiliary heater on sealing flange and lay connector aside.
 

Removing and installing fuel line for auxiliary/supplementary heater

If the fuel line for metering pump -V54- is to be disconnected from fuel delivery unit:
–  Open lower clamp -3- on sealing flange -1-.
The fuel system is pressurised.Risk of injury due to fuel which may spurt out.Wear eye protection.Wear protective gloves.Release pressure: place clean cloth around connection and carefully open connection.
–  Do not open upper clamp -4-.
–  Pull fuel line -2- together with grommet off sealing flange.
If a new fuel delivery unit is installed:
–  Remove fuel line → Anchor.
 

Removing and installing fuel line for auxiliary/supplementary heater

–  Remove fuel delivery unit → Chapter.
–  The connection on the fuel delivery unit -2- must be opened.
–  To do this, cut off sealing piece -3- on connection -1-.
–  Cut it off on the respective marking line -arrow-.
–  Deburr edges of cutting point.
–  Prevent any dirt or swarf from entering the fuel delivery unit.
–  Check fuel delivery unit for soiling, and clean it as necessary.
–  Install fuel delivery unit → Chapter.
 

Removing and installing fuel line for auxiliary/supplementary heater

Installing fuel line:
–  Insert fuel line -3- in connection -5-.
–  Insert fuel line to stop -arrow-.
–  While doing this, fit grommet -1- over connection.
–  Renew lower clamp -4-.
–  If the fuel line or grommet has been renewed, the upper clamp must be renewed as well.
–  Renew clamps -2- and -4-, if they have been opened.
–  Secure hose connections with the hose clips corresponding to original equipment.
Specified torques
→ Chapter „Assembly overview - fuel delivery unit and fuel gauge sender“
 

Removing and installing fuel line for auxiliary/supplementary heater

Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive
Special tools and workshop equipment required     Special wrench -T10202-   ...

Senders and sensors
...

Other materials:

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Special tools and workshop equipment required         Removal lever -80 - 200     Release pliers -VAS 6427 Removing ...

Technical data
General repair instructions Repairing electrical wiring harnesses and connectors → Electrical System, General Information; Rep. gr.97 Releasing and dismantling connector housings → Electrical Sys ...

Component protection
First read and observe the introductory information and safety warnings Some electronic components and control units are fitted with component protection as standard, e.g the radio or navigation system. Component protection was developed as a protective mechanism in order to: Prevent any ...

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