Volkswagen Golf / Golf Plus. Manual - part 324

– Remove bench seat ⇒  General body repairs, interior; Rep.

Gr.  72 ; Rear seat; Removing and installing seat bench .

– Remove covers and separate electrical connectors -arrows-.
– Remove centre and rear silencers.

– Secure exhaust system to underbody using wire.
– Remove rear propshaft ⇒  Manual gearbox; Rep. Gr.  39 ; Final

drive, differential, differential lock

Vehicles from 06/2007 (single part propshaft):
– Remove complete exhaust system 

⇒ page 186

 .

– Remove complete propshaft ⇒  Propshaft and rear final drive;

Rep. Gr.  39 ; Repairing propshaft - Golf .

Continuation for all vehicles:

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.

– Pull off adapter cable on four-wheel drive control unit -J492- .

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     Rep. Gr.20 - Fuel supply system

 

– Slowly lower fuel tank.

Note

The filler neck must be “guided out” between body and rear axle.

To do this, take the fuel tank off engine and gearbox jack -V.A.G

1383 A- with the assistance of a 2nd mechanic.

4.3.2

Installing fuel tank

– Clip in cable for four-wheel drive control unit -J492- on fuel

tank.

– With the aid of a 2nd mechanic, guide the filler neck in between

rear axle and body. Then place the fuel tank on the engine and

gearbox jack -V.A.G 1383 A- .

– Raise the fuel tank slowly up to the installation position and

secure -arrows-.

– Fit adapter cable on four-wheel drive control unit -J492- .
The remaining installation steps are carried out in the reverse se‐

quence. In the process, note the following:
♦ Install breather and fuel lines free of kinks.
♦ Do not interchange supply line and return line (return line blue

or with blue marking, supply line black).

♦ Ensure that line connections are firmly seated.
♦ Check earth connection on fuel tank and body to filler neck.

4.4

Removing and installing fuel gauge

sender 2 -G169-

• The fuel tank should be no more than half full

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Ensure that the fuel gauge sender is not bent.

♦

If necessary, drain fuel tank using fuel extractor -VAS 5190- .

⇒ page 128

♦

Note safety precautions before starting work 

⇒ page 114

 .

♦

Observe rules for cleanliness 

⇒ page 115

 .

Removing:
– First check whether a coded radio is fitted. If so, obtain anti-

theft coding.

– With the ignition switched off, disconnect battery earth strap.

⇒  Electrical system; Rep. Gr.  27 ; Disconnecting and con‐

necting batteries .

– Remove bench seat ⇒  General body repairs, interior; Rep.

Gr.  72 ; Rear seat; Removing and installing seat bench .

– Remove left cover (as seen facing direction of normal travel)

from fuel gauge sender 2 -G169- .

– Disconnect electrical connectors.
– Open locking ring using wrench -T10202- .

– Pull fuel gauge sender 2 -G169- upwards slightly and unclip it

from the suction-jet pump.

Installing:

Caution

When installing do not bend fuel gauge sender 2 -G169- float

arm.

– Place fuel gauge sender 2 -G169- in fuel tank.

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– Place a new flange seal dry into opening in fuel tank and mois‐

ten inside (contact to flange) only with fuel.

– Note installation position of fuel gauge sender 2 -G169-

⇒ page 128

– Check for correct position of seal.

– Tighten locking ring using wrench -T10202- . Specified torque:

110 Nm.

– Fit connectors.
– Install cover.
– Install bench seat. ⇒  General body repairs, interior; Rep. Gr. 

72 ; Rear seat; Removing and installing seat bench .

4.5

Removing and installing suction-jet

pump

Note

♦

On vehicles with four-wheel drive, fuel has to be pumped from

the area of fuel gauge sender 2 -G169- to the fuel delivery unit

by means of a suction jet pump due to the shape of the fuel

tank.

♦

Checking is only necessary when the engine stops due to lack

of fuel, even though the fuel gauge shows that the tank is still

1/4 full.

Procedure
– Remove fuel delivery unit 

⇒ page 123

 .

– Pull return hose of suction-jet pump out of fuel delivery unit

-arrow-.

– Separate quick-release coupling of supply line from suction-

jet pump on Y-piece of fuel delivery unit.

– Remove fuel gauge sender 2 -G169- 

⇒ page 135

 .

– Now the suction-jet pump can be pulled out from side of fuel

gauge sender 2 -G169- (left side of vehicle).

– Check that the fuel lines on suction-jet pump are fitted securely

and are not damaged.

– Additionally check suction-jet pump for possible soiling.

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