Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 735

4

Repair Information

⇒ “4.1 Wire Routing and Securing”, page 5
⇒ “4.2 General Repair Information”, page 5

4.1

Wire Routing and Securing

WARNING

There is a risk of damaging lines.
It is possible to damage the wires with the moving or hot com‐

ponents.

– Route wire in the original wiring guide.
– Ensure sufficient clearance to moving or hot components.
♦ Mark the individual fuel and vacuum lines for the Evaporative

Emission (EVAP) canister system as well as the electrical

wires before disconnecting and/or removing them. This will

prevent a mix-up when reconnecting them. If necessary, draw

sketches or take pictures.

4.2

General Repair Information

Complete the Following Steps Before Starting Work on the Fuel

Supply System:
♦ Before starting work, place the extracting hose on an exhaust

extractor that is switched on near the fuel tank assembly open‐

ing.

♦ This extracts the fuel vapors.
♦ If no exhaust extraction system is available, a radial fan (as

long as motor is not in air flow) with a displacement greater

than 15 m 

3

/h can be used.

♦ Do not let fuel come in contact with bare skin. Wear fuel-re‐

sistant gloves.

♦ Disable the current to the Transfer Fuel Pump - G6- . Refer to

⇒ Wiring diagrams, Troubleshooting & Component locations.

♦ Drain the fuel tank. Refer to

⇒ “1.3 Fuel Tank, Draining”, page 35

 .

20 – Fuel Supply

1

Fuel Tank

⇒ “1.1 Overview - Fuel Tank”, page 6
⇒ “1.2 Fuel Tank, Removing and Installing”, page 11
⇒ “1.3 Fuel Tank, Draining”, page 35

1.1

Overview - Fuel Tank

⇒ “1.1.1 Overview - Fuel Tank, Vehicles with Multi-Link Rear Axle

and FWD”, page 6
⇒ “1.1.2 Overview - Fuel Tank, Vehicles with FWD and Torsion

Beam Rear Suspension”, page 8
⇒ “1.1.3 Overview - Fuel Tank, Vehicles with Fuel Tank Leak De‐

tection”, page 10

1.1.1

Overview - Fuel Tank, Vehicles with Multi-Link Rear Axle and FWD

1 - Fuel Line

❑ Vehicles with Parking

Heater

❑ To Metering Pump -

V54-

❑ Do not kink
❑ To disconnect, press

the release button on

the connecting piece

❑ The connector cou‐

plings must »audibly«

engage when locking.

❑ Pull on the connector

coupling to check for se‐

cure fit.

❑ Connector Couplings,

Disconnecting. Refer to

⇒ “4.1 Connector Cou‐

plings, Disconnecting”,

page 62

 .

2 - Fuel Supply Line

❑ To the engine
❑ Clipped to the fuel tank
❑ Do not kink
❑ To disconnect, press

the release button on

the connecting piece

❑ The connector cou‐

plings must »audibly«

engage when locking.

❑ Pull on the connector

coupling to check for se‐

cure fit.

❑ Connector Couplings,

Disconnecting. Refer to

⇒ “4.1 Connector Couplings, Disconnecting”, page 62

 .

3 - Bleeder Line

❑ To the EVAP Canister Purge Regulator Valve 1 - N80-
❑ Clipped to the fuel tank
❑ Do not kink
❑ To disconnect, press the release button on the connecting piece
❑ The connector couplings must »audibly« engage when locking.
❑ Pull on the connector coupling to check for secure fit.
❑ Connector Couplings, Disconnecting. Refer to 

⇒ “4.1 Connector Couplings, Disconnecting”, page 62

 .

4 - Bracket

❑ For Fuel Pump Control Module - J538-
❑ Fuel Pump Control Module - J538- , removing and installing. Refer to

⇒ “8.2  Fuel Pump Control Module J538 , Removing and Installing”, page 116

 .

5 - Bolt

❑ 20 Nm +90°
❑ Replace after removing.

6 - Bolt

❑ 8 Nm +90°
❑ Replace after removing.

7 - Cap

❑ Turn until it clicks into place.
❑ Attached to the fuel filler door unit with fastener

8 - Bolt

❑ 8 Nm +90°
❑ Replace after removing.
❑ For securing the fuel filler neck

9 - Ground Connection

❑ For the fuel filler neck
❑ For discharging electrostatic charge

10 - Bleeder Line

❑ To the EVAP Canister
❑ Clipped to the fuel tank
❑ Do not kink
❑ To disconnect, press the release button on the connecting piece
❑ The connector couplings must »audibly« engage when locking.
❑ Pull on the connector coupling to check for secure fit.
❑ Connector Couplings, Disconnecting. Refer to 

⇒ “4.1 Connector Couplings, Disconnecting”, page 62

 .

11 - Bleeder Line

❑ To the EVAP Canister
❑ Clipped to the fuel tank
❑ Do not kink
❑ To disconnect, press the release button on the connecting piece
❑ The connector couplings must »audibly« engage when locking.
❑ Pull on the connector coupling to check for secure fit.
❑ Connector Couplings, Disconnecting. Refer to 

⇒ “4.1 Connector Couplings, Disconnecting”, page 62

 .

12 - Fuel Tank

❑ Removing and Installing. Refer to

⇒ “1.2.1 Fuel Tank, Removing and Installing, Vehicles with Multi-Link Rear Axle”, page 11

 .

13 - Bolt

❑ 20 Nm + 90°
❑ Replace after removing.

14 - Nut

❑ 2 Nm
❑ For the heat shield

15 - Heat Shield

❑ For the fuel tank

16 - Mounting Strap
17 - Bolts

❑ 20 Nm + 90°
❑ Replace after removing.

1.1.2

Overview - Fuel Tank, Vehicles with FWD and Torsion Beam Rear Sus‐

pension

1 - Cap

❑ Turn until it clicks into

place.

❑ Attached to the fuel filler

door unit with fastener

2 - Ground Connection

❑ For the fuel filler neck

3 - Bolt

❑ 8 Nm +90°
❑ Replace after removing.

4 - Locking Ring

❑ 110 Nm ± 5 Nm

5 - Seal

❑ Replace
❑ Install dry

6 - Fuel Delivery Unit

❑ Overview. Refer to

⇒ “2.1 Overview - Fuel

Delivery Unit/Fuel Level

Sensor”, page 51

 .

❑ Removing and Installing

⇒ “2.2 Fuel Delivery

Unit/Fuel Level Sensor,

Removing and Instal‐

ling”, page 52

❑ With Fuel Level Sensor

- G-

❑ Fuel Level Sensor - G- ,

Removing and Instal‐

ling. Refer to

⇒ “2.3  Fuel Level Sen‐

sor G , Removing and

Installing”, page 56

 .

❑ With the Transfer Fuel Pump - G6-
❑ Transfer Fuel Pump - G6- , Checking. Refer to 

⇒ “8 Fuel Pump”, page 81

 .