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Volkswagen Golf Service & Repair Manual: Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

Volkswagen Golf Service & Repair Manual / Fuel supply system - Petrol engines / Fuel supply, gas operation / Fuel delivery unit, fuel gauge sender / Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

1 -  Fuel pump control unit -J538-
Check with → Vehicle diagnostic tester
Removing and installing → Chapter
2 -  Electrical connector
For fuel pump control unit -J538-.
Make sure it is engaged properly; pull to check that plug-in connector is correctly engaged
3 -  Electrical connector
For fuel system pressurisation pump -G6-.
Make sure it is engaged properly; pull to check that plug-in connector is correctly engaged
4 -  Electrical connector
For fuel gauge sender -G- and fuel gauge sender 2 -G169-
Make sure it is engaged properly; pull to check that plug-in connector is correctly engaged
5 -  Locking ring
Loosen and tighten with wrench -T10202-.
110 Nm
6 -  Flange
Removing and installing → Chapter
7 -  Seal
Renew after removing
Install dry.
8 -  Fuel gauge sender 2 -G169-
Carry out electrical test → Vehicle diagnostic tester
Removing and installing → Chapter
9 -  Mounting with suction-jet pump
No replacement part available
Welded to fuel tank
Function → Chapter.
10 -  Fuel gauge sender -G-
Carry out electrical test → Vehicle diagnostic tester
Removing and installing.
11 -  Fuel delivery unit
With fuel system pressurisation pump -G6-.
With integrated fuel filter
The fuel filter cannot be renewed individually
Carry out electrical test on fuel pump with → Vehicle diagnostic tester
After installing, fill vehicle with at least 5 litres of fuel.
Removing and installing → Chapter
12 -  Seal
Renew after removing
Install dry.
13 -  Locking ring
Remove and tighten with wrench -T10202-.
110 Nm
14 -  Fuel line
To engine.
Do not kink
To disconnect from flange, press release tab on connection piece
Connect so it engages audibly
Press in again and then pull to check that plug-in connector is correctly engaged

 
     
Installation position of fuel delivery unit
The arrow -3- on the fuel tank must line up with the mark -2- on the sealing flange -1-.
 

Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with front-wheel drive
1 -  Fuel delivery unit With fuel system pressurisation pump -G6-. With integrated fuel filter; cannot be renewed individually. ...

Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with auxiliary heater
1 -  Fuel delivery unit With fuel system pressurisation pump -G6-. With integrated fuel filter; fuel filter cannot be renewed separately ...

Other materials:

Assembly overview - rear window
1 -  Rear window Removing and installing → Chapter 2 -  PUR adhesive sealant Cross section of bead: -width b- = 7 mm, -height a- = 10 mm (including precoating, residual material on window glass and w ...

Removing and installing steering rack, RHD vehicles, except for e-Golf
Special tools and workshop equipment required Ball joint puller -T10187- Torque wrench -V.A.G 1331- Torque wrench -V.A.G 1332- Engine and gearbox jack -V.A.G 1383 A-   Removing ...

Renewing LSF Lambda probe (4-pin)
  Note If necessary, replace attachment parts, cable ties or marking rings to match the uniform probe to the defective probe as specified. Do not repair Lambda probe wires, since this can result in malfunctions. ...

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