Volkswagen Golf Variant / Jetta. Manual - part 415

 

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Volkswagen Golf Variant / Jetta. Manual - part 415

 

 

T10202- .

– Pull the fuel delivery unit and gasket out of the fuel tank open‐

ing.

Note

If the fuel delivery unit is to be replaced then drain old delivery

unit before disposal.

Follow all waste disposal regulations.

Installing:
Install in reverse order of removal. Note the following:
• Locking ring tightening specification -item 14-

⇒ Item 14 (page 232)

 / -item 16- 

⇒ Item 16 (page 234)

 .

• Do not bend the Fuel Level Sensor - G- when inserting the fuel

delivery unit.

• Replace the gasket on the fuel delivery unit if damaged and

insert it dry into the fuel tank opening.

• Coat the seal with fuel only for installing the fuel delivery unit.
• Note the installation position of the fuel delivery unit flange:
• For the Jetta from MY 2005 through 2010, Jetta SportWagen

(US)/Jetta Wagon (Canada) for MY 2009 and Jetta SportWa‐

gen (US)/Golf Wagon (Canada) from MY 2010. Refer to

⇒ Fig. ““Fuel Delivery Unit Flange Installation Position”“ , page

232

 .

• For Jetta from MY 2011. Refer to

⇒ Fig. ““Fuel Delivery Unit Flange Installation Position”“ , page

235

 .

• Route the fuel lines without kinks.
• Do not interchange supply and return line (return line blue,

supply line black).

• Make sure the line connections are secure.
– Observe the notes after connecting the Battery - A- . Refer to

⇒  Electrical Equipment; Rep. Gr.  27 ; Battery; Battery, Dis‐

connecting and Connecting .

4.7

Fuel Level Sensor - G- , Removing and

Installing

DANGER!

♦ Observe safety precautions when working on fuel supply.

Refer to

⇒ “1 Safety Precautions when Working on Fuel Supply

System”, page 223

 .

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 224

 .

Always pay attention to these instructions before and during

work.

4. Fuel Supply System Components    

243

⇒ “4.6 Fuel Delivery Unit, Removing and Installing”,

page 241

 .

– Move the Fuel Level Sensor - G- slightly to the side and up‐

ward at the same time.

– Push the tabs -arrows- to the side if it is not possible to release

the sensor.

– Write down the cable color coding for reinstallation.
– Disconnect the connectors -1 through 3-.

– Bend back the hooks on the connector.
Installing:
Install in reverse order of removal. Note the following:
– Connect the connectors -1 through 3-.
– Pay attention to the color coding.
– Pull on the connectors to make sure they are secure.
– Insert the Fuel Level Sensor - G- in the guide on the fuel de‐

livery unit and push down until it engages.

– Install the fuel delivery unit. Refer to

⇒ “4.6 Fuel Delivery Unit, Removing and Installing”,

page 241

 .

244

Connector Couplings, Disconnecting

Special tools and workshop equipment required
♦ Lever - Fuel Line - T10468-
Connector Coupling Allocation

Note

The connector couplings for fuel, vacuum and vent lines are

color-coded. There is either a colored dot on the connector

coupling or the release button is the corresponding color.

The connector couplings must »audibly« engage when lock‐

ing.

Pull on the connector coupling to check for secure fit.

Connector Coupling

Color Coding on the Connector

Coupling

Fuel supply

Black

Fuel Return Line

Blue

Ventilation

White, beige

Vacuum

Green

WARNING

The fuel supply line is under pressure. Wear protective eye‐

wear and protective clothing to avoid injury and contact with

skin. Place a cleaning cloth around the connection point before

loosening  hose  connections.  Remove  the  hose  connection

carefully to reduce the pressure.

Version 1
Connector coupling with right and left release buttons -arrows-.
Opening
It is necessary to counterhold the fuel separating point -1-.
– Insert the Lever - Fuel Line - T10468- between the heat shield

and the fuel line stop -arrow- -2- and counterhold it.

5. Connector Couplings, Disconnecting    

245

the direction of -arrow B-.

Follow the color coding during installation. Refer to 

⇒ page 245

The connector couplings must »audibly« engage when locking.

– Pull on the connector coupling to check for secure fit.
Version 2

Coupling with pull release -arrow-
Opening
– Push the connector coupling -1- in the direction of -arrow A-.
– Pull the pull release -2- in the direction of -arrow B-.
– Pull the connector coupling -1- off the fuel line -3- in the direc‐

tion of -arrow B-.

Follow the color coding during installation. Refer to 

⇒ page 245

The connector couplings must »audibly« engage when locking.

246

 

 

 

 

 

 

 

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