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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Golf IV (1997 release)

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Volkswagen Golf 4
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Fuel System
Cars with petrol engines
Removal and installation of the fuel pump / fuel level sensor
Removal and installation of the fuel filter (petrol engines)
Adjusting accelerator cable
Removing and installing air cleaner housing
Remote check of elements of fuel system
Checking the fuel pump
Checking the fuel pump relay
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Removal and installation of the fuel pump / fuel level sensor



Location on the mounting flange of the supply and return fuel lines

1 - the fuel supply line;

2 - the fuel return line


Fixing the fuel level sensor


1, 2 - fixing clamps;

3, 4 - electric sockets

Withdrawal

PERFORMANCE ORDER
1. Turn off the ignition and remove a wire of weight from the accumulator.
2. Remove the rear seat back peremesite carpet and unscrew the cover, located above the fuel pump / fuel level sensor.
3. Disconnect the electrical connector of the fuel pump / fuel level sensor.
4. Note that the pipeline supplying the fuel under pressure. Before disconnecting, remove the fuel pressure in the fuel system. To do this, loosen the clamp on the fuel line, then close the connection with rags and, being careful, remove the fuel hose from the union. To protect the eyes from fuel use protective glasses.
5. Loosen and remove the clamp from the mounting flange fittings feeder (2) and return (1) fuel (see. Fig. Location on the mounting flange of the supply and return fuel lines). Close the ends of pipelines suitable stoppers.
6. Using a special tool VW-3217, remove the flange nut. In the absence of a special tool, unscrew the nut of the flange using a wooden block and a hammer.
7. Remove from the opening of the fuel tank mounting flange and O-ring.
8. On the inner side of the mounting flange, label and disconnect the fuel hoses.
9. Drain the fuel from the fuel pump into suitable containers.
10. Carefully disconnect the fuel level sensor. To do this, disconnect the electrical connectors (3 and 4) with a screwdriver loosen the fixing clamps (1 and 2) and by moving the sensor down, remove it (see. Fig. Mounting the fuel level sensor).

Setting

PERFORMANCE ORDER
1. Place the fuel level sensor in the bracket and pressing on the locking clips fix it.
2. On the back of the mounting flange connect fuel lines.
3. Install the fuel pump with fuel level sensor in the fuel tank. Before installing the seal ring dip fuel.
4. Turn the fuel pump clockwise and lock it in the fuel tank.
5. Install the mounting flange so that the mark on the flange is aligned with the mark on the fuel tank (see. Fig. Mounting the fuel level sensor).
6. Screw the flange nut and use special tool VW-3217, tighten it to 60 Nm.
7. Put on the mounting flange fitting supply and return fuel hoses and fix their collars. The arrows indicate the direction of unions on the fuel flow. The return fuel hose in black.
8. Connect the electrical connector to the mounting flange.
9. Replace the cover over the mounting flange and tighten the screws.
10. Check the correctness and reliability of fastening of fuel and air hoses to the fuel tank.
11. Replace the carpeting and rear seat.
12. Connect the ground cable to the battery.




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Cars with petrol engines
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Removal and installation of the fuel filter (petrol engines)

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