VW Golf manuals

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:

Removing and installing temperature sensor -G18- and overheating sensor -G189
Removing     –  Dismantling and assembling auxiliary heater → Chapter. –  Remove bolt -1- (4 Nm) and remove retaining spring -2-. ...

Removing and installing connecting Bowden cable
Removing –  Remove backrest cover and backrest padding → Chapter.     –  Swing mounting bracket for backrest release mechanism -1- upwards as far as ...

Safety precautions when working on cooling system
Risk of scalding due to hot coolant The cooling system is under pressure when the engine is hot. Hot steam/hot coolant can escape - risk of scalding. –  Wear protective gloves. –  Wear eye protection. –  ...

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