Fuel Tank/Fuel System - Revised
84VW03 Applies To CONVERTIBLESCIROCCO
1984
Group
20
Subject
Fuel System
Part Identifier N/A
Key Points
Fuel tank/fuel system components
A113
Number
84-01
September 28, 1984
From February 1984 the Rabbit Convertible and the Scirocco are produced with a 13.7 gallon fuel tank.. (previously 10.5 gallons)
Note
Due to extensive changes to the body, the larger tank cannot be installed in earlier vehicles.
The following additional changes have been made:
^ tank free of pressure
^ gravity valve without pressure retainer
^ sender for fuel gauge with transfer fuel pump
^ fuel reservoir with strainer between transfer and main fuel pumps
The following repairs and checking procedures are included in this circular:
Repair Page
fuel system, removing/installing 2, 3, 4
fuel tank, removing/installing 5
For information on checking fuel pumps, delivery capacity, fuel pump relay and check valve, refer to 1985 Golf, GTI, Jetta Repair Manual, Groups 20 and 25.
CAUTION
When working on the fuel system ensure that everything is kept clean. Observe the following rules:
1 Thoroughly clean all connections and the adjacent area before detaching fuel unions.
2 Place parts that have been removed on a clean surface and cover with plastic wrap, paper or lint free cloth
3 Install only clean parts
^ only unpack replacement parts immediately before installation
^ do not use parts which have been stored unpacked
4 Components which have been opened should be covered or sealed carefully if the repair cannot be completed immediately
5 When the fuel system is open:
^ do not use compressed air
^ do not move vehicle unless absolutely necessary
WARNING
Disconnect battery when working on fuel system. Never smoke when working with fuel or have anything in the area that can ignite it. Always replace seals and fuel hose clamps.
Fuel tank, removing
Work sequence
- remove large breather hose 3 from filler neck
- pull gravity valve down (pipes 1 and 2 remain on)
- detach fuel pump bracket from body and lower pump
- remove screw 3 for fuel tank
- remove hose 1 from fuel pump
- remove hose 2 (blue) from return line
- disconnect brake hoses at rear axle on both sides (black arrow)
- detach rear axle from body on both sides (white arrows), swing down and suspend on handbrake cable guides
- unhook rubber exhaust hangers
- remove fuel tank fasteners and lower tank until vent hoses can be disconnected
- disconnect fuel gauge sending unit wire
- remove fuel tank
Fuel tank, installing
- install in reverse sequence
- bleed brakes
Note
When connecting hoses, turn clamps so they do not contact the body.
After installation, coat tank with long term underbody sealant, Part No. D 003 500