Pro
te
c
t
ed
b
y
co
p
y
rig
h
t.
C
o
p
y
in
g
fo
r
pr
iv
a
t
e
o
r
c
o
m
m
e
r
c
ia
l
p
u
rp
o
s
e
s
,
i
n
p
a
rt
o
r i
n
w
h
o
le
,
is
n
o
t
p
e
r
m
it
t
e
d
u
n
l
e
s
s
a
ut
ho
r
i
s
ed
b
y
V
olk
sw
a
ge
n AG
.
V
olk
s
w
a
g
en
AG do
es
n
ot g
uar
ante
e
or a
c
c
ep
t
a
ny
li
a
b
i
li
t
y
w
ith
r
e
s
p
e
c
t
t
o
th
e
c
o
rr
e
c
t
n
e
s
s
o
f
in
fo
r
m
a
tio
n
in
th
is
d
o
c
um
en
t.
C
o
py
rig
ht b
y
V
olk
sw
a
ge
n
A
G.
1.2
Safety precautions when working on
fuel supply system
Caution
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
When removing and installing fuel gauge sender or fuel pump
(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Even before work commences, the extraction hose of an ac‐
tivated fume extraction system has to be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
radial fan with a displacement greater than 15 m
3
/h can be
used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.3
Rules for cleanliness
When working on the fuel supply and injection system, pay careful
attention to the following „6 rules“ for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes or similar).
♦ When system is open, do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
Amarok 2011 ➤
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
160
Rep. gr.20 - Fuel supply system
