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:

Test prerequisites
Check wheel suspension, wheel bearing assembly and steering for excessive play and damage. Tread depth difference of no more than 2 mm on one axle. Tyres inflated to correct pressures. ...

Sprayable sealant
Designation: Sprayable sealant -D 476 KD1 M2-, grey Sprayable sealant -D 476 KD2 M2-, black Issued 08.2012 Product description Sprayable sealant -D 476 ...

Notes on releasing and dismantling contact housings
  Note Observe the general notes on repairs to the vehicle electrical system → Chapter. To release, always use the correct release tools. Under no circumstances should the contacts be pulled out of the ...

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