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Home >> Volkswagen >> 2005 >> Jetta TDI, Automatic >> Repair and Diagnosis >> Engine Performance >> Testing & Diagnosis >> 1.9L - Fuel Supply System - BKC, BLS, BRM & BXE (A5 Platform) >> 20 Fuel Supply System >> Removal And Installation >> Fuel Cooler

Fuel Cooler

Special tools and workshop equipment required 

Removing 

-- Read safety precautions before beginning work FUEL SUPPLY SYSTEM SAFETY PRECAUTIONS .

-- Observe the rules for cleanliness CLEAN WORKING CONDITIONS .

NOTE:

The fuel cooler is located in the return line to the fuel tank. It is attached to the underbody of the vehicle.

-- Remove right underbody trim -arrows-.

Fig 1: Identifying Right Vehicle Floor Cover
GWWA10-1663Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the drip tray for workshop crane under the vehicle.

WARNING:
  • The fuel or fuel lines in fuel system can become very hot (danger of scalding)!
  • In addition, the fuel system is under pressure! Release pressure by carefully loosening the connection!
  • Wear protective goggles and protective gloves when working on the fuel system!

-- Separate the fuel lines at the fuel cooler.

-- Remove the nuts -arrows-.

Fig 2: Identifying Fuel Cooler Nuts
GWWN20-0702Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing 

Installation is performed in reverse order. When doing this note the following: