VW Golf manuals

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

Special tools and workshop equipment required
   
Wrench -T10202-
 

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

Torque wrench -V.A.G 1332-
 

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

Removal wedge -3409-
Removing
–  Observe safety precautions → Chapter.
–  Observe rules for cleanliness → Chapter.
–  Fuel tank must not be more than 3/4 full. This ensures that the fill level is below the flange of the fuel delivery unit.
–  Draining fuel tank → Chapter
Golf SV:
–  Remove right rear seat → General body repairs, interior; Rep. gr.72.
 

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

–  Partially detach cover -1- in floor covering at parting line -arrow-.
–  Do not detach cover completely from floor covering in order to ensure it is reinstalled in the correct installation position.
–  Detach it just enough that the cover can be folded upwards.
–  Fold up cover in -direction of arrow-.
Golf and Golf Estate:
–  Remove rear bench seat → General body repairs, interior; Rep. gr.72.
 

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

Continuation for all vehicles:
–  Unclip cover -1- for flange at retaining tabs -arrows-, using removal wedge -3409-.
 

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

–  Unclip sealing grommet -1- downwards from cover -2-.
–  Push cover -2- back along wiring harness -3-.
 

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

–  Release and pull off connector -1- on sealing flange.
–  If fitted, detach connector -2- for metering pump -V54- of auxiliary heater on sealing flange and lay connector aside.
 

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

–  Disconnect fuel line -1- on sealing flange. Separate plug-in connectors → Chapter.
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.
 
–  If fitted, remove fuel line -2- leading to metering pump -V54- for auxiliary heater from sealing flange.
–  To do this, loosen lower hose clip.
 

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

–  Pull sealing flange -2- for a short distance out of the opening in the fuel tank.
–  Remove seal -1- at the opening in the fuel tank.
–  Carefully pull out fuel delivery unit with fuel gauge sender -G- through opening of fuel tank.
–  Turn and tilt it as necessary while doing so.
–  When removing the fuel delivery unit, ensure that the float arm of the fuel gauge sender is not bent.
–  Place a cloth underneath the fuel delivery unit to catch any escaping fuel.
  Note
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.
Installing:
Install in reverse order. In the process, note the following:
  Note
Separate plug-in connectors → Chapter.
Renew seal if damaged.
 

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

–  Insert dry seal -1- for fuel delivery unit into opening in fuel tank.
–  When inserting fuel delivery unit, ensure that fuel gauge sender is not bent.
–  Coat inner side of seal -1- with fuel.
–  Press down sealing flange -2- against spring force.
–  Bring sealing flange to installation position.
 

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

–  The arrow -3- on the fuel tank must line up with the mark -2- on the sealing flange -1-.
–  When sealing flange is inserted, ensure that seal is not damaged or squashed.
 

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

–  Tighten locking ring using wrench -T10202-.
 

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

–  Push fuel line -1- onto sealing flange until it engages audibly.
–  If present, install fuel line -2- leading to metering pump -V54- for auxiliary heater on sealing flange → Auxiliary heaters; Rep. gr.82.
 

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

–  Connect connector -1-.
–  If present, attach connector -2- for metering pump -V54- of auxiliary heater to sealing flange.
–  Ensure connectors -1- are firmly seated by pulling.
–  After installing fuel delivery unit, fill fuel tank with at least 5 litres of fuel.
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.
Specified torques
→ Chapter „Assembly overview - fuel delivery unit and fuel gauge sender“
 

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

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 ...

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

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