Contents - Volkspage

Fuel system: single-point injection models 4A.7
7.16 Line fuel pump and accumulator unit
1 Line fuel pump 2 Accumulator
the rear of the vehicle. Access is from the
underside of the vehicle (see illustration).
17 Refer to Section 9 and depressurise the
fuel system.
18 Park the vehicle on a level surface, apply
the handbrake, select first gear (manual
transmission) and chock the front roadwheels.
Raise the rear of the vehicle and support it
securely on axle stands (see “Jacking and
vehicle support”).
19 Slacken the hose clips and disconnect the
fuel lines from either side of the pump. If the
clips are of the crimp type, snip them off with
cutters and replace them with equivalent size
worm drive clips upon reconnection.
20 Prise off the metal retaining clip and lower
the pump unit away from its mounting
bracket. Disconnect the wiring harness at the
connector.
Refitting
21 Refitting is reversal of removal.
8 Fueltankremoval
and refitting
A
Warning:
!
Removal
Observe the
precautions in Section 1 before
working on any component in
the fuel system.
1 Before the tank can be removed, it must be
drained of as much fuel as possible. As no
drain plug is provided, it is preferable to carry
out this operation with the tank almost empty.
2 Disconnect the battery negative cable and
position it away from the terminal. Using a
hand pump or syphon, remove any remaining
fuel from the bottom of the tank.
3 Refer to Section 7 and carry out the
following:
a) Disconnect the wiring harness from the
top of the pump sender unit at the
multiway connector.
b) Disconnect the fuel supply and return
hoses from the pump/sender unit
4 Select first gear and chock the front
roadwheels. Remove the centre caps and
slacken the right hand rear roadwheel bolts.
5 Raise the rear of the vehicle, support it
securely on axle stands (see “Jacking and
vehicle support”) and remove the right hand
rear roadwheel.
6 Refer to Chapter 4C and unhook the
exhaust tailbox from its mounting bracket.
7 With reference to Chapter 9, detach the
handbrake cable and its mounting bracket
from the rear axle beam.
8 Refer to Chapter 10 and unbolt the right
hand axle beam mounting from the vehicle
underside. Support the axle on blocks to
prevent straining the bushes.
9 Position a trolley jack under the centre of
the tank. Insert a block of wood between the
jack head and the tank to prevent damage to
the tank surface. Raise the jack until it just
takes the weight of the tank.
10 Working inside the rear right hand wheel
arch, slacken and withdraw the screws that
secure the tank filler neck to the inside of the
wheel arch. Open the fuel filler flap and peel
the rubber sealing flange away from the
bodywork.
11 Detach the breather hoses from the filler
neck, making a note of their order of fitment.
12 Remove the retaining screws from the
tank securing straps, keeping one hand on the
tank to steady it, as it is released from its
mountings.
13 Lower the jack and tank away from the
underside of the vehicle; disconnect the
charcoal canister vent pipe from the port on
the filler neck as it is exposed. Locate the
earthing strap and disconnect it from the
terminal at the filler neck.
14 If the tank is contaminated with sediment
or water, remove the fuel lift pump/sender unit
(see Section 7 ) and swill the tank out with
clean fuel.
Refitting
15 Refitting is the reverse of the removal
procedure noting the following points.
a) When lifting the tank back into position
make sure the mounting rubbers are
correct/y positioned and take great care
to ensure that none of the hoses become
trapped between the tank and vehicle
body.
b) The large breather hose must be secured
to the filler neck before the tank is
secured in position.
c) Ensure that all breather pipes and hoses
are correctly routed, free of kinks and
securely held in position with their
retaining clips.
d) Reconnect the earth strap to its terminal
on the filler neck.
e) Tighten the tank retaining strap bolts to
the specified torque.
f) If a new tank has been fitted, it must be
coated with undersea/ before the vehicle
is brought back into service.
g) On completion, refill the tank with fuel and
check for signs of leakage prior to taking
the vehicle out on the road.
2 Refer to Section 5 and locate the fuel pump
relay. Remove the relay from its socket, then
crank the engine for a few seconds. The
engine may fire and run for a while, but
continue cranking until it stops. The fuel
injector should have opened enough times
during cranking to considerably reduce the
line fuel pressure.
3 Switch off the ignition ,then disconnect the
battery negative cable and position it away
from the terminal
4 Place a suitable container beneath the
connection/union that is to be disconnected,
and have a rag ready to soak up any escaping
fuel not being caught by the container.
5 Slowly loosen the connection or union nut
(as applicable) to avoid a sudden release of
pressure and position the rag around the
connection to catch any fuel spray which may
be expelled. Once the pressure has been
released, disconnect the fuel line completely
and insert plugs to minimise fuel loss and to
prevent the entry of dirt into the fuel system.
1 If a fault appears in the fuel injection system
first ensure that all the system wiring
connectors are securely connected and free
of corrosion. Then ensure that the fault is not
due to poor maintenance; ie, check that the
air cleaner filter element is clean, the spark
plugs are in good condition and correctly
gapped, the cylinder compression pressures
are correct, the ignition timing is correct and