Volkswagen Golf / Golf Plus. Manual - part 322

 

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Volkswagen Golf / Golf Plus. Manual - part 322

 

 

-V.A.G 1594 C- .

– Switch on ignition. The LED must light up for about 2 seconds.
If LED does not light up
– Check actuation of fuel pump relay and wiring for open circuit

or short circuit. ⇒ Vehicle diagnosis, testing and information

system VAS 5051

If LED lights up (voltage supply OK):
– Remove fuel delivery unit. 

⇒ page 123

– Check that electrical wiring between flange and fuel pump is

connected and has continuity.

If no open circuit can be found:
– Renew fuel delivery unit. 

⇒ page 123

3.6.2

Checking current draw of fuel pump

– Pull 4-pin connector off fuel delivery unit flange.
– Set multimeter to measuring range 20 A and connect in series

between contacts -1- of connector and fuel pump using auxil‐

iary cables from auxiliary measuring set -V.A.G 1594 C- .

Note

The current pick-up clamp of multimeter -V.A.G 1715- can also

be attached to an auxiliary cable between contacts -1- of con‐

nector and fuel pump.

– Connect contacts -4- of connector and fuel pump using an

auxiliary cable from auxiliary measuring set -V.A.G 1594 C- .

– Start engine and run at idling speed.
– Measure current draw of fuel pump: Specification: max. 7.5

Amperes.

– If the measured value is not within specifications:
– Renew fuel delivery unit. 

⇒ page 123

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

126

     Rep. Gr.20 - Fuel supply system

 

drive

Observe safety precautions 

⇒ page 114

 .

Observe rules for cleanliness 

⇒ page 115

 .

Assembly overview - fuel tank 

⇒ page 127

 .

Emptying fuel tank 

⇒ page 128

 .

Removing and installing fuel tank 

⇒ page 132

 .

Removing and installing fuel gauge sender 2 -G169-

⇒ page 135

 .

Removing and installing suction jet pump 

⇒ page 137

Checking fuel pump 

⇒ page 125

 .

4.1

Assembly overview - fuel tank

1 - Supply line

❑ Black
❑ Check for secure seat‐

ing.

2 - Return line

❑ Blue
❑ Check for secure seat‐

ing.

3 - Seal

❑ Renew if damaged.
❑ When installing, fit dry in

fuel tank opening

❑ Moisten with fuel only

when installing flange.

4 - Fuel delivery unit

❑ Removing and installing

⇒ page 123

 .

❑ Checking fuel pump

⇒ page 125

 .

❑ Note installation posi‐

tion on fuel tank

⇒ page 128

 .

❑ With fuel gauge sender

-G-

❑ Removing and installing

fuel gauge sender

⇒ page 124

 .

5 - Locking ring, 110 Nm

❑ Check for secure seat‐

ing.

❑ Remove and install us‐

ing wrench -T10202- .

6 - Tank flap unit

❑ With rubber cup
❑ Removing and installing ⇒  General body repairs, exterior; Rep. Gr.  55 ; Tank flap unit; Removing and

installing fuel tank flap unit .

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

4. Fuel tank, vehicles with four-wheel drive    

127

 

8 - Securing bolt

❑ Tighten to 1.5 Nm.

9 - Earth connection

❑ Check for secure seating.

10 - 10 Nm
11 - Suction-jet pump

❑ Clipped onto fuel gauge sender 2 -G169-
❑ Removing and installing 

⇒ page 137

 .

12 - Fuel gauge sender 2 -G169-
13 - Fuel tank

❑ When removing, support using engine and gearbox jack -V.A.G 1383 A- .
❑ Removing and installing 

⇒ page 132

 .

14 - Securing strap

❑ Note installation position.

15 - 25 Nm

❑ To secure the securing straps for the fuel tank, only bolts with loose washers must be used. If other bolts

are used, the securing straps could be twisted whilst tightening. Bolts ⇒  ETKA (electronic parts cata‐

logue) .

❑ Renew.

16 - Heat shield

❑ Riveted to exhaust pipe mounting

Installation position of flange for fuel delivery unit and fuel gauge

sender 2 -G169-
The marking on the flange must align with the marking on the fuel

tank -arrow-.

Note

The marking on the fuel tank is not clearly visible.

4.2

Emptying fuel tank

Special tools and workshop equipment required
♦ Fuel extractor -VAS 5190-

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

128

     Rep. Gr.20 - Fuel supply system

 

⇒ page 114

 .

Emptying fuel tank when fuel pump is intact 

⇒ page 129

 .

Emptying fuel tank if it is more than 

3

/4 full 

⇒ page 130

 .

Emptying fuel tank if it is less than 

3

/4 full 

⇒ page 131

 .

4.2.1

Emptying fuel tank, bleeding fuel system

when fuel pump is intact

Special tools and workshop equipment required
♦ Diagnostic tester
♦ Fuel extractor -VAS 5190-
♦ Adapter for fuel extraction -VAS 5190 /3 -

WARNING

Fuel supply line is pressurised. Wear eye protection and pro‐

tective clothing to avoid possible injury and skin contact. Before

loosening hose connections, wrap a cloth around the connec‐

tion. Then release pressure by carefully pulling hose off con‐

nection.

Note

Press in securing ring to release fuel lines.

– Pull off supply line -arrow- and catch escaping fuel with a cloth.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

4. Fuel tank, vehicles with four-wheel drive    

129

 

 

 

 

 

 

 

 

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