Volkswagen Golf Service & Repair Manual: Removing and installing fuel delivery unit/fuel gauge sender, vehicles with
front-wheel drive
| Special tools and workshop equipment
required |
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| Torque wrench -V.A.G 1332- |
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Observe safety precautions
→ Chapter. |
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Observe rules for cleanliness
→ Chapter. |
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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. |
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Draining fuel tank
→ Chapter |
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Remove right rear seat
→ General body repairs, interior; Rep. gr.72. |
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Partially detach cover -1- in
floor covering at parting line -arrow-. |
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Do not detach cover completely from floor covering in order
to ensure it is reinstalled in the correct installation
position. |
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Detach it just enough that the cover can be folded upwards. |
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Fold up cover in -direction of arrow-. |
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Remove rear bench seat
→ General body repairs, interior; Rep. gr.72. |
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| Continuation for all vehicles: |
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Unclip cover -1- for flange at
retaining tabs -arrows-, using
removal wedge -3409-. |
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Unclip sealing grommet -1-
downwards from cover -2-. |
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Push cover -2- back along
wiring harness -3-. |
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Release and pull off connector -1-
on sealing flange. |
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If fitted, detach connector -2-
for metering pump -V54- of auxiliary heater on sealing flange
and lay connector aside. |
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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.
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If fitted, remove fuel line -2-
leading to metering pump -V54- for auxiliary heater from sealing
flange. |
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To do this, loosen lower hose clip. |
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Open locking ring using wrench -T10202-. |
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Carefully lift flange of fuel delivery unit. |
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Insert dry seal -1- for fuel
delivery unit into opening in fuel tank. |
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When inserting fuel delivery unit, ensure that fuel gauge
sender is not bent. |
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Coat inner side of seal -1-
with fuel. |
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Press down sealing flange -2-
against spring force. |
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Bring sealing flange to installation position. |
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The arrow -3- on the fuel tank
must line up with the mark -2- on
the sealing flange -1-. |
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When sealing flange is inserted, ensure that seal is not
damaged or squashed. |
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Tighten locking ring using wrench -T10202-. |
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Push fuel line -1- onto sealing
flange until it engages audibly. |
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If present, install fuel line -2-
leading to metering pump -V54- for auxiliary heater on sealing
flange
→ Auxiliary heaters; Rep. gr.82. |
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If present, attach connector -2-
for metering pump -V54- of auxiliary heater to sealing flange. |
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Ensure connectors -1- are
firmly seated by pulling. |
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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.
| → Chapter „Assembly overview - fuel delivery unit and fuel gauge
sender“ |
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1 -
Fuel delivery unit
With fuel system pressurisation pump -G6-.
With integrated fuel filter; fuel filter cannot be renewed
separately ...
Special tools and workshop equipment
required
Special wrench -T10202-
...
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Note
Assembly overview - fuel delivery unit/fuel gauge sender, vehicles with
auxiliary heater
Removing and installing fuel delivery unit/fuel gauge sender, vehicles with
four-wheel drive