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10Removing and Installing Engine
Edition 11.96
- Detach the earth cable -1- from the top en-
gine/gearbox connecting bolt.
- Unplug connector -2- and pull out of the fix- ture.
- Take off cable -3- and -4- at the starter.
- Detach cables from the fixture at the starter and place to the side. Unbolt fixture.
- Detach fuel feed pipe -1- and fuel return flow
pipe -2- (press release catches).
Important!
Fuel feed pipe is pressurised! Place cleaning ragsaround the connection point before detaching thehose connections. After this, release the pressure
by carefully detaching the hose.
- Unplug the following electrical connections:
1 - Knock sensor I (G61) (black)
2 - Knock sensor II (G66) (brown)
3 - Engine speed sender (G28) (grey)
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Edition 11.96
Removing and installing parts of the fuel supply system
Notes:
Hose connections are secured with screw-
type, spring strap or clamp-type clips.
Always replace clamp-type clips by spring
strap clips or screw-type clips.
Fuel hoses at the engine must be securedonly with spring strap clips. It is not permitted
to use clamp-type or screw-type clips.
Always replace seals and gaskets when
carrying out removal and installation work.
Pay attention to safety precautions page 20-4.
Pay attention to rules for cleanliness page 20-4.
Removing and installing parts of the activatedcharcoal filter system page 20-12.
Servicing throttle mechanism page 20-12.
Setting throttle cable page 20-13.
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20Fuel Supply System
Edition 08.96
Removing and installing fuel tank with attached parts and fuel filter
1 - Overflow hose
2 - O-ring
Replace
3 - Gravity valve To remove, unclip valve and lift up and out of filler neck
Inspect valve for blockage valve vertical: open valve tilted 45°: closed. 4 - Vent pipe
To activated charcoal filter page 20-12, item 5
5 - Cap Replace seal if damaged
6 - Tensioning ring
7 - Rubber bowl
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20Fuel Supply System
Edition 08.96
Safety precautions when carrying out work on fuel supply system
Important!
Fuel system is pressurised! Place cleaning ragsaround the connection point before opening the
system. Then, release pressure by carefullyloosening the connection point.
Pay attention to the following points when re- moving and installing the fuel gauge sender or the fuel pump (fuel delivery unit) from the fuel tank: Fuel tank should be not more than
2/3 full.
The extraction hose of an exhaust extraction system should be placed close to the assembly opening of the fuel tank and the extraction system switched on before commencing work in order to extract the fuel vapours which are released. If no exhaust extraction system is available, it is possible to use a radial fan with a delivery volume of more than 15 m
3/h (motor not
positioned in the air flow).
Avoid skin contact with fuel! Wear fuel- resistant gloves!
Rules for cleanliness
Pay careful attention to the following „5 rules“for cleanliness when carrying out work on the fuel supply/fuel injection system: Thoroughly clean connection points and the surrounding area before disconnecting.
Place removed parts down on a clean
surface and cover over. Do not use fluffing cloths!
Carefully cover over or seal opened com- ponents if repairs are not carried out imme-
diately.
Install only clean parts: Do not remove replacement parts from their wrapping until just before installing. Do not use parts which have been stored unwrapped (e.g. in tool boxes etc.).
If the system is open:
Avoid working with compressed air, if possible.
Avoid moving the vehicle, if possible.
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Edition 08.96
Removing and installing fuel delivery unit
Pay attention to safety precautions ⇒
page 20-4.
Pay attention to rules for cleanliness ⇒ page
20-4. Special tools, testers and aids required♦ Wrench for union nut MP 1-227
Removing
- If car is fitted with a coded radio set, deter- mine coding, if necessary.
- Switch off ignition (if not already off) and dis- connect earth strap at the battery.
- Unbolt cover (below the rear seat).
- Disconnect feed and return flow pipes from the flange of the fuel delivery unit (press release buttons).
- Release 4-pin connector from the flange at the fuel tank and unplug.
- Use wrench MP 1-227 to unscrew union nut.
- Pull fuel delivery unit and seal out of the
opening of the fuel tank.
Note:
If the delivery unit is still filled with fuel, emptybefore replacing.
Installing Installation is performed in the reverse order; pay attention to the following points:
Notes:
♦When inserting the fuel delivery unit, ensure
that the fuel gauge sender is not bent.
♦Moisten seal of the flange with fuel beforeinstalling.
♦Ensure the fuel hoses are tightly connected.
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20Fuel Supply System
Edition 08.96
- Pay attention to installation position:
Marking on the flange should be aligned with the marking on the fuel tank -arrows-.
Blue return flow pipe -1- to connectionwith marking -R-.
Black feed pipe -2- to connection with marking -V-.
Removing and installing fuel gauge sender
Removing
- Remove fuel delivery unit page 20-5.
- Release connector tabs of cables -3- and -4-
and unplug.
- Use a screwdriver to lift the retaining tabs -1- and -2- and pull fuel gauge sender down
and off -arrow-.
Installing
- Insert fuel gauge sender into the guides at the fuel delivery unit and push up until it locks in place.
Removing and installing fuel tank
Pay attention to safety precautions page 20-4.
Pay attention to rules for cleanliness page
20-4 Special tools, testers and aids required Engine/gearbox jack (e.g. V.A.G 1383 A)
Fuel extraction unit (e.g. V.A.G 1433 A)
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Edition 08.96
Removing
- If car is fitted with a coded radio set, pay attention to coding; determine if necessary.
- Switch off ignition (if not already off), and disconnect earth strap at the battery.
- Empty fuel tank with fuel extraction unit (e.g. V.A.G 1433 A).
- Remove rear suspension: ⇒ Running Gear; Repair Group 42; Servicing rear suspension; Removing and installing rear suspension.
- Unbolt cover (below the rear seat).
- Release 4-pin connector from the flange at fuel tank and unplug.
- Open fuel filler flap and lever out tensioning ring in rubber bowl (around filler neck).
- Push rubber bowl through to the inside.
- Remove rear right wheelhouse liner.
- Unscrew fuel filler neck below the wheel- house liner.
- Remove cover below the fuel tank -arrows-
(if fitted).
- Disconnect return flow pipe -2- (blue), feed
pipe -1- (black) and breather pipe -3- (white) at the front right of the fuel tank (press release buttons).
- Place engine/gearbox jack (e.g. V.A.G 1383 A) below the fuel tank to support it.
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20Fuel Supply System
Edition 08.96
- Detach screw connections -arrow- at the
front left and at the retaining straps.
- Lower fuel tank. Installing Installation is performed in the reverse order; pay attention to the following points:
- Connect fuel pipes to the flange of the fuel
delivery unit:
Blue return flow pipe -1- to connection marked with -R-.
Black feed pipe -2- to connection marked with -V-.
Connecting remote control
Special tools, testers and aids required Remote control V.A.G 1348/3A with adapter
cable V.A.G 1348/3-2
Procedure
- Open cover of the fuse box on the left-hand side of the dash panel.
- Remove fuse 28 at the fuse carrier (left-hand row, 5th large fuse form the top).
- Connect remote control V.A.G 1348/3A with
adapter cable V.A.G 1348/3-2 to the fuse base of fuse 28 -arrow-.
- Connect clamp to car battery (+).
