Volkswagen Golf Service & Repair Manual: Removing and installing fuel delivery unit/fuel gauge sender, vehicles with
four-wheel drive
| Special tools and workshop equipment
required |
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| – |
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. |
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Unclip cover -1- for flange on
right at retaining tabs -arrows-,
using removal wedge -3409-. |
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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. |
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| – |
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. |
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| – |
Open locking ring using wrench -T10202-. |
| – |
Carefully lift flange of fuel delivery unit. |
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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. |
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| – |
Release connector -arrow-.
Disconnect connector -1- from right
flange. |
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| – |
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. |
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| – |
Carefully pull out fuel lines through opening in fuel tank. |
| – |
Disconnect supply line for suction-jet pump
-1- and supply line
-2-. |
| 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.. |
| → Chapter „Assembly overview - fuel tank“ |
| → Chapter „Assembly overview - fuel delivery unit and fuel gauge
sender“ |
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Special tools and workshop equipment
required
Wrench -T10202-
...
Removing
–
Observe safety precautions
→ Chapter.
–
Observe rules for cleanliness
...
Other materials:
Assembly overview - seat heating element
1 -
Seat padding
Allocation
→ Electronic Parts Catalogue
2 -
Heater element
Driver seat: heated seat cushion for front passenger seat -Z6-
Front passenger seat: heated seat cushion for front passenger seat -Z8
All ...
Assembly overview - rear vehicle level sender, torsion beam axle
Note
The rear left vehicle level sender -G76- is only available as a
replacement part complete with coupling rod and upper and lower
retaining plates.
1 -
Electrical connector
2 -
Bolt
5 Nm
...
Adjusting installation position of tail light
Note
Installation position can only be corrected on tail light
cluster on body.
Removal and installation are described for the left side.
Removal and installation on the right side are carried out in
the same w ...
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Removing and installing fuel delivery unit/fuel gauge sender, vehicles with
front-wheel drive
Removing and installing fuel line for auxiliary/supplementary heater