Page 113 of 136
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Edition 11.96
Removing and installing radiator
Notes:
Always replace seals and gaskets.
Lifting vehicle with lift platform page 10-1,
Removing and installing engine.
Special tools, testers and aids required Torque wrench 5...50 Nm (e.g. V.A.G 1331)
Wire
Removing
- Drain coolant page 19-3.
- Unplug connector of thermostatic switch
(F18) -1- and separate plug connections -2- and -3- at the fan shroud (press locking cat- ches).
- Detach coolant hoses at connection fitting of the radiator (pull off retaining clip).
Models with air conditioning
- Unscrew the 4 bolts -arrows- attaching the
condenser.
Important!
The refrigerant circuit of the air conditioning sys-tem must not be opened.
Note: In order to avoid damage to the condenser andalso to the refrigerant pipes/hoses, ensure that
the pipes and hoses are not over-tensioned,kinked or bent.
Page 118 of 136
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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
Page 122 of 136
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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)
Page 128 of 136
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20Fuel Supply System
Edition 08.96
1 - Solenoid valve 1 (N80)
Testing operation and actuation:
1.8 ltr./92 kW Engine, Motronic Fuel Injection and Ignition System; Repair Group 24;
Testing tank breather; Testing solenoid valve 1 for activated charcoal filter
2 - Connector
3 - Vent pipe From gravity valve at fuel tank page
20-2, item 4
To disconnect, press release buttons on connector
4 - Throttle valve control unit
5 - Activated charcoal filter with solenoid valve 1 (N80)
Installation point: in right of engine compartment
To remove, take off PAS reservoir andpush to the side
6 - Spring nut
Removing and installing parts of the activated charcoal filter system Servicing throttle mechanism
1 - Throttle cable Adjust by re-positioning locking ele- ment on detent page 20-13
2 - Locking element
3 - Accelerator pedal
4 - Spacer bush
5 - Bearing bush
6 - Washer
7 - Stop screw
8 - 20 Nm
Page 129 of 136
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Edition 08.96
Adjusting throttle cable
Notes:
The throttle cable is very sensitive to kinking
and should be treated with particular care
when installing.
A single slight kink can subsequently resultin the cable fracturing when driving. Throttle
cables which have been kinked, musttherefore not be installed.
When installing, ensure that the throttle cableis properly aligned between its supporting
points and the cable attachment points.
Special tools, testers and aids required Spring stretcher rod
Procedure
- Attach throttle cable to the accelerator pedal and to the cam of the throttle valve control unit.
- Pull off locking element for throttle cable at the detent.
- Depress accelerator pedal to full throttle position.
Note:
A second mechanic is required for this step ordepress accelerator pedal using spring stretcher
rod supported against steering wheel.
Models with manual gearbox
- Adjust throttle cable by repositioning the detent on the support bracket so that full throttle position is reached at the throttle
valve lever.
Models with automatic gearbox
- Adjust throttle cable by repositioning the detent on the support bracket so that the throttle valve has opened fully and the kickdown switch is heard to click.
For all models
- Release accelerator pedal or remove stretcher rod.
- After completing adjustment, check idling speed and full throttle stop of the throttle valve.
