VW Golf manuals

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

Special tools and workshop equipment required
   
Special wrench -T10202-
 

Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

Removal wedge -3409-
Removing
–  Move front seats to foremost position.
–  Remove rear bench seat → General body repairs, interior; Rep. gr.72.
–  Disconnect earth wire from battery terminal → Electrical system; Rep. gr.27.
–  If necessary, empty fuel tank → Chapter.
 

Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

–  Unclip cover -1- for flange on right at retaining tabs -arrows-, using removal wedge -3409-.
 

Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

–  Unclip sealing grommet -1- downwards from cover -2-.
–  Push cover -2- back along wiring harness -3-.
The fuel system is pressurised.Risk of injury due to fuel which may spurt out.Wear eye protection.Wear protective gloves.Release pressure: place clean cloth around connection and carefully open connection.
 

Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

–  Disconnect connectors -1 and 2- as well as fuel line -3- from flange, and pull them off.
–  If fitted, remove fuel line leading to metering pump -V54- for auxiliary heater from sealing flange → Chapter.
 

Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

–  Open locking ring using wrench -T10202-.
–  Carefully lift flange of fuel delivery unit.
 

Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

–  Pull right flange -2- for a short distance out of the opening in the fuel tank.
–  Remove seal -1- at the opening in the fuel tank.
 

Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

–  Release connector -arrow-. Disconnect connector -1- from right flange.
 

Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

–  Carefully pull out fuel delivery unit -1- with fuel gauge sender -G--2- through opening in fuel tank by turning and tilting it as required.
  Note
When removing the fuel delivery unit, ensure that the float arm of the fuel gauge sender is not bent.
If delivery unit is to be renewed, old delivery unit must be drained before disposal.
Observe environmental regulations for disposal.
Check fuel tank for foreign bodies and dirt.
 

Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

–  Carefully pull out fuel lines through opening in fuel tank.
–  Disconnect supply line for suction-jet pump -1- and supply line -2-.
Installing
Installation is carried out in the reverse order; note the following:
Risk of explosion of fuel tank caused by fuel pump activation.Risk of severe injuries and burns.If a new or completely empty fuel tank has been installed, fill it immediately with at least 5 litres of fuel.
  Note
Push on supply line for suction-jet pump and supply line until it engages audibly.
Insert new seal for fuel delivery unit dry into opening of fuel tank.
When inserting fuel delivery unit, ensure that fuel gauge sender is not bent.
Coat only inner side of seal with fuel.
Check connectors are secured properly by pulling.
–  Note installation position of flange when installing → Fig..
Specified torques
→ Chapter „Assembly overview - fuel tank“
→ Chapter „Assembly overview - fuel delivery unit and fuel gauge sender“
 

Removing and installing fuel delivery unit/fuel gauge sender, vehicles with four-wheel drive

Removing and installing fuel delivery unit/fuel gauge sender, vehicles with front-wheel drive
Special tools and workshop equipment required     Wrench -T10202-   ...

Removing and installing fuel line for auxiliary/supplementary heater
Removing –  Observe safety precautions → Chapter. –  Observe rules for cleanliness ...

Other materials:

Additional information
Technical Service Handbook with measures for rectifying latest malfunctions. Workshop manual for service work specific to model → Heating, air conditioning; Rep. gr.87. → Current ...

Removing and installing turn signal bulb
  Note Removal and installation are described for the left side. Removal and installation on the right side are carried out in the same way. Removing –  Remove tail light cluster on body & ...

Removing and installing rear underbody cover – petrol/diesel
  Note The removal and installation procedures may have to be modified slightly depending on engine fitted. –  Loosen lock washer -3-. –  Unclip spreader rivet -2- and remove bolt -4-. –  Remove rea ...

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