Fuel Supply System ΓÇô Petrol Engines Volkswagen R GmbH (1)

Service
Workshop Manual
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Fuel supply system – petrol engines, Volkswagen R ss c
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CJXC CJXB CYF CJX DLR
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
20 - Fuel supply system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg D4B803919C8

Golf 2013 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf Variant 2017 ➤
Fuel supply system – petrol engines, Volkswagen R GmbH - Edition 07.2017
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when using testers and measuring instruments during a road test . . . . 1
1.3 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine number/engine
AG. Volkswagedata
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3 General
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ks information . . . . . . . s. n.o.t g. u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
b ara
3.1 risedRules for cleanliness when working on nauxiliary/supplementary
tee heater and fuel system . . 5
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4au Repair instructions . . . . . . . . . . . . . . . . . . a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ss
4.1 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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4.2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
spec
urposes, in part or in wh
1.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1 Assembly overview - fuel delivery unit and fuel gauge sender . . . . . . . . . . . . . . . . . . . . . .
rrectne 28
2.2 Removing and installing fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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2.4 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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3 Plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
mer
atio
3.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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4 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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5.1 Connection diagram - activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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5.2 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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5.3 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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5.4 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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5.5 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cted
54
agen
Prote AG.
6 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2 Removing and installing accelerator pedal module GX2 . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.1 Checking fuel system pressurisation pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.2 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.3 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Contents i
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ii Contents
00 – Technical data
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⇒ “1.2 Safety precautions when using testers and measuring in‐
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struments during a road test”, page 1
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1.1 Safety regulations for working on fuel supply
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Risk of injury from highly pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible.
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Before opening the fuel system:
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– Wear protective goggles.
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– Wear protective gloves.
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– To release pressure, wrap a clean cloth around the connection
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and carefully loosen the connection.

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Procedure for releasing pressure in high pressure fuel system ⇒ Cop py
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Danger of fire caused by escaping fuel
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When the battery is connected and the driver door opens, the door
contact switch activates the fuel pump. Escaping fuel can ignite
and cause a fire.
– Disconnect voltage supply to fuel pump before opening the
fuel system.
1.2 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.
1. Safety information 1
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1.3 Safety measures when working on vehicles with a start/stop system
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Risk of injury due to unexpected motor start
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If the vehicle’s start/stop system is activated, the engine can start
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whether the start/stop system is activated.
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– Deactivate start/stop system by switching off the ignition.
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2 Rep. gr.00 - Technical data

2 Identification
⇒ “2.1 Engine number/engine data”, page 3
2.1 Engine number/engine data

Engine data
Codes CJXB CJXC CYFB
Displacement l 1.984 1.984 1.984
Power kW at rpm 206/5100 to 6500 221/5500 to 6200 215/5400 to 6200
Torque Nm at rpm 380/1800 to 5100 380/1800 to 5500 380/1900 to 5300
Bore ∅ mm 82.5 82.5 82.5
Stroke mm 92.8 92.8 92.8
Compression ratio 9.3:1 9.3:1 9.3:1
RON 981) 981) 981)
Ignition/injection system FSI FSI FSI
MPI MPI MPI
Exhaust gas recirculation No No No
Exhaust gas temperature regulation No No No
Charging Exhaust turbocharg‐ Exhaust turbocharger Exhaust turbocharg‐
er er
Knock control yes yes yes
Intercooler yes yes yes
Lambda regulation yes yes yes
Camshaft timing adjustment yes yes yes
Variable intake manifold yes yes yes
Secondary air system No No No
Valves per cylinder 4 4 4
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Cylinder shut-off No
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Codes CJXD CJXG DJHA

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Torque Nm at rpm 380/1850 to 5100 380/1850 to 5700 400/2000 to 6500

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Bore ∅ mm 82.5 82.5 82.5

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Stroke mm 92.8 92.8 92.8

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Compression ratio 9.3:1 9.3:1 9.3:1

RON 981) 981) 981)
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MPI MPI MPI
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Charging Exhaust turbocharg‐ Exhaust turbocharg‐ Exhaust turbocharg‐

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agen 2. Identification
Codes CJXD CJXG DJHA

Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Cylinder shut-off No No No
• 1) Unleaded petrol RON 95 can also be used, though power
is reduced
Codes DJHB DJJA DLRA

Torque Nm at rpm 380/1850 to 5300 380/1900 to A5300
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RON 981) 95 95
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Charging Exhaust turbocharg‐ Exhaust turbocharg‐ Exhaust turbocharg‐
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Firing order 1-3-4-2 1-3-4-2 1-3-4-2
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Cylinder shut-off No No No
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3 General information
⇒ “3.1 Rules for cleanliness when working on auxiliary/supple‐
mentary heater and fuel system”, page 5
3.1 Rules for cleanliness when working on

auxiliary/supplementary heater and fuel
system
Even slight soiling can cause faults. For this reason, observe the
following rules for cleanliness when working on the fuel supply
system and injection system:
AG. gen AG Volkswa
♦ Carefully clean connection points and othe agen
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dry thoroughly before gu
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♦ Seal open pipes and connections
ss immediately with clean
plugs for example from the engine bung set - VAS 6122- .
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♦ Place removed parts on a clean surface and cover them over.
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Use only lint-free cloths.
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♦ If repair work cannot be performed immediately, carefully cov‐
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♦ Install only clean parts; do not remove new parts from pack‐
es, in part or in w
aging until immediately before installing. Do not use parts that
t to the co
have been stored outside their packaging (e.g. in tool boxes).
♦ When the system is open, do not work with compressed air or
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move the vehicle.
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♦ Protect disconnected electrical connectors from dirt and water,

and reconnect them only when dry.
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3. General information 5
4 Repair instructions
⇒ “4.1 Routing and attachment of lines”, page 6
⇒ “4.2 General repair instructions”, page 6
4.1 Routing and attachment of lines

Risk of damage to lines
Lines may become damaged by moving or hot components.
– Route lines in their original positions.
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– Ensure there is sufficient clearance to moving ory Vhot compo‐
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♦ Mark fuel lines, vacuum lines, pipes/hoses for activated char‐
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coal filter system and electrical wiring etc. before removal so
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they can be re-installed in the original positions and correctly
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connected. Where necessary, make sketches or take photo‐
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4.2 General repair instructions
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Before starting work on the fuel supply system, the following steps
must be performed:
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♦ Before starting work, the extraction hose of a switched-on ex‐
l purpos
haust gas extraction system must be laid near to the assembly

opening of the fuel tank.
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♦ The extraction hose is used to extract fuel fumes.
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♦ If no exhaust gas extraction system is available, a radial fan

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with a displacement greater than 15 m3/h can be used provid‐

or
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ing that motor is not in air flow.

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♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

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♦ Interrupt power supply to fuel system pressurisation pump -
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♦ Drain fuel tank ⇒ page 22 . Prote AG.

20 – Fuel supply system

1 Fuel tank
⇒ “1.1 Assembly overview - fuel tank”, page 7
⇒ “1.2 Removing and installing fuel tank”, page 11
⇒ “1.3 Emptying fuel tank”, page 22
1.1 Assembly overview - fuel tank

⇒ “1.1.1 Assembly overview - fuel tank”, page 7
⇒ “1.1.2 Assembly overview - fuel tank, region North America”,
page 9
1.1.1 Assembly overview - fuel tank
WARNING
Risk of explosion of fuel tank. If a new or completely empty fuel

tank has been installed, it must be filled immediately with at
least 5 litres of fuel. The fuel pump must not be allowed to run
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1. Fuel tank 7
1 - Breather line
❑ To activated charcoal fil‐
ter
❑ Do not kink
❑ Clipped onto fuel tank.
❑ To pull off, press release
button on connection
❑ Connect so it engages
audibly
❑ Press in again and then
pull to check that plug-in
connector is correctly
engaged
2 - Breather line
ter
❑ Do not kink
❑ Connect so it engages
audibly
❑ Press in again and then
pull to check that plug-in
connector is correctly
engaged
3 - Bolts
❑ 20 Nm
4 - Fuel tank
❑ Removing and installing
⇒ page 11 agen
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5 - Securing strap
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6 - Bolt aut
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❑ 20 Nm
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7 - Nut
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❑ For heat shield

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9 - Securing strap on right

10 - Bolt
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❑ 20 Nm
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11 - Fuel line
❑ To engine
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❑ Do not kink
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❑ To pull off, press release button on connection

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❑ Connect so it engages audibly

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❑ Press in again and then pull to check that plug-in connector is correctly engaged
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12 - Fuel pump control unit - J538-
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❑ Removing and installing ⇒ page 69
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8 Rep. gr.20 - Fuel supply system

13 - Bolt
❑ 8 Nm
14 - Cap
❑ Screw in until engages . Voaudibly
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❑ Secured Vto swa flap unit by meansdoof
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15 - Bolthoris tee
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❑ ss aFor securing fuel filler neck. ac
❑ For diverting static electricity ⇒ page 9 .
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❑ 8 Nm
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Earth connection for fuel filler neck
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– Connect earth connection as shown in illustration.
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– Ensure that the following connectors are seated correctly:
♦ Connector -2- for earth connection on threaded ring -3- of fuel
filler neck
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– Hook contact tab -1- of earth connection into mounting hole
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on fuel tank -4-. Press in spacer bush -5-.
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WARNING
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Risk of explosion due to electrostatic discharge.

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♦ After installation, use an ohmmeter to check electrical

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1.1.2 Assembly overview - fuel tank, region

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WARNING

1. Fuel tank 9
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❑ 8 Nm
7 - Earth connection
❑ For fuel filler neck
❑ For diverting static elec‐
tricity ⇒ page 11 .
8 - Cap
❑ Screw in until engages audibly
❑ Secured to tank flap unit
9 - Breather line
❑ To activated charcoal filter
❑ Do not kink
❑ Separating and connecting plug-in connectors ⇒ page 37
10 - Breather line
❑ To activated charcoal filter
❑ Do not kink
❑ Separating and connecting plug-in connectors ⇒ page 37
11 - Bolt
❑ 8 Nm
12 - Bolts
❑ Qty. 3
❑ 20 Nm
13 - Fuel tank

14 - Securing strap on left

15 - Bolt
❑ 20 Nm
16 - Nut
❑ For heat shield
❑ 2 Nm
Earth connection for fuel filler neck, region North America

♦ Connector -4- for earth connection on threaded ring -1- of fuel
filler neck
– Engage contact tab -3- of earth connection in mounting hole
on fuel tank, and press in spacer bush -2-.
WARNING

1.2 Removing and installing fuel tank

⇒ “1.2.1 Removing and installing fuel tank”, page 11
⇒ “1.2.2 Removing and installing fuel tank, region North America”,
page 17
1.2.1 Removing and installing fuelolktank

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1. Fuel tank 11
♦ Engine and gearbox jack - V.A.G 1383 A-

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Note safety precautions ⇒ page 1 .
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– Move front seats to foremost position.

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– Separate electrical connector -arrow-.

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tween floor panel and fuel tank with your finger.
– At the same time, carefully pull fuel pump control unit - J538-
-1- out of mounting -in direction of arrow B- by grasping hold
of wiring harness -3-.
– Guide fuel pump control unit - J538- out towards interior be‐
tween fuel tank and floor panel.
– Separate electrical connectors -1- and -2-.
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1. Fuel tank 13
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– Unclip breather lines -1 and 2- from retainer -arrow- on sub‐

frame.
– Remove propshaft ⇒ Propshaft and rear final drive, Volkswa‐
gen R GmbH; Rep. gr. 39 ; Propshaft; Removing and installing
propshaft .
– Disconnect connector -1- for Haldex clutch.
WARNING
The fuel line is under pressure.

Fuel poses danger of injury to eyes and skin.
Wear protective goggles and protective clothing to avoid injury
and contact with the skin. Wrap a cloth around the connection
before loosening hose connections. Then reduce pressure by
carefully opening the connection.

– Disconnect lines -1 and 2- at right side of underbody.
– Place engine and gearbox jack - V.A.G 1383 A- underneath

for support and prop up fuel tank as shown in illustration.
WARNING
AG. Volkswagen AG d
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1. Fuel tank 15
– In addition, a second mechanic will be required to support the

fuel tank at the rear by hand.
– Remove bolts -1 … 5-.
Note
For reasons of clarity, the fuel tank is shown without the engine
and gearbox jack - V.A.G 1383 A- .
– Carefully lower fuel tank with engine and gearbox jack - V.A.G
1383 A- . Unclip lines from fuel tank while doing so.
– Remove fuel tank downwards (turning it sideways as re‐
quired).
– In addition, a second mechanic will be required to guide out
fuel filler neck by hand.
Installing
Install in reverse order of removal, observing the following:
WARNING
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Risk of explosion of fuel tank.VoIflkaswnew
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inserted into opening in body.
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connecting and connecting battery .
Specified torques
• ⇒ “1.1 Assembly overview - fuel tank”, page 7 .
1.2.2 Removing and installing fuel tank, re‐

gion North America
♦ Removal wedge - 3409-
1. Fuel tank 17
AG. Volkswagen AG d
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co Vo
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♦ There may still be a certain amount of fuel in the fuel tank, after
the extraction procedure has been completed. Therefore, al‐
ways proceed with extreme care when removing and installing
the fuel tank.
Removing
Note safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 5 .
battery .
individual seats .
– Drain fuel tank ⇒ page 22 .
– Unclip cover -1- at retaining tabs in direction of -arrows- using
removal wedge - 3409- .

– Press up tab -2- in -direction of arrow A-; to do so, reach be‐

tween floor panel and fuel tank with your finger.
– Guide fuel pump control unit - J538- AGout
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Note
In order to prevent the ingress of dirt, seal the opening of the fuel
filler neck with a clean plug.

– Pull breather lines -1- off activated charcoal filter. To do so,

disconnect plug-in connectors ⇒ page 37 .
– Unscrew bolts -3-.
– Remove propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing and
installing propshaft .
1. Fuel tank 19
– Disconnect connector -1- for Haldex clutch.
WARNING

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– Disconnect line -1- from underbody on right. ut
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WARNING
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Risk of accident caused by weight of fuel tank.
n
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♦ The fuel tank must be empty when removing.

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spec
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1383 A- . Unclip lines from fuel tank while doing so.
t to the co
– Remove fuel tank downwards (turning it sideways as re‐
quired).
rrectne
– In addition, a second mechanic will be required to guide out
fuel filler neck by hand.
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Installing
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WARNING
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Note
♦ Press on fuel lines again, and pull them to check that plug-in
connector is correctly engaged.
♦ When plugging in electrical connectors, make sure they en‐
gage correctly.
1. Fuel tank 21
– Ensure that connector -4- is fitted securely on metal ring -1-.

– Contact tab -3- must be attached to fuel tank and secured with
spacer bush -2-.
WARNING

– Verify that fuel pipes and breather pipes are clipped onto fuel
tank.
– Position fuel tank with securing straps at underbody, using
engine and gearbox jack - V.A.G 1383 A- .
– When installing fuel tank, ensure that fuel filler neck is correctly
inserted into opening in body.
– Connect battery. Observe required procedures after connect‐
ing battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
Specified torques
• ⇒ “1.1 Assembly overview - fuel tank”, page 7 .
1.3 Emptying fuel tank

⇒ “1.3.1 Emptying fuel tank if it is more than 3/4 full”, page 22
⇒ “1.3.2 Emptying fuel tank if it is less than 3/4 full”, page 24 olkswagen AG
en AG. V wag does
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– Use insulating tape to make a mark -arrow- at dimension -a-

measured from end of extraction hose of fuel extractor -
VAS 5190A- or fuel extractor - VAS 5190- .
Four-wheel drive vehicles: -a- = 960 mm.

Caution
Secure earth wire of fuel extractor to a bare metal part of the

body.
– Push extraction hose of extraction unit into fuel tank until pre‐
viously attached marking -arrow- on hose coincides with filler
neck -2-. G. Volkswagen nA AG do
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♦ If the extraction hose catches on the non-return valve when

ole,
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being extracted, do not apply force to pull the extraction hose

out.
t to the co
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return valve manually. Ensure that your arm does not come
rrectne
into contact with fuel.

s
– Pull extraction hose out carefully.

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Note
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♦ When no more fuel is extracted, the tank is emptied just

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♦ If work has to be done on fuel delivery unit or on fuel gauge

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sender , proceed as follows ⇒ page 24 :

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1. Fuel tank 23
AG. Volkswagen AG d
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♦ Special wrench - T10202-
♦ Fuel extractor - VAS 5190A- (for E 85 fuel)
♦ Fuel extractor - VAS 5190- (not shown)

agenFuel supply system
AG. Volkswagen AG d – petrol engines,
Volkswagen R GmbH - Edition 07.2017
oes
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pt
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h re
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spec
fuel.
es, in part or in w
t to the co
♦ There may still be a certain amount of fuel in the fuel tank, after
the extraction procedure has been completed. Therefore, al‐
ways proceed with extreme care when removing and installing
rrectness of i
the fuel tank.
l purpos
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– Remove bench seat ⇒ General body repairs, interior; Rep. gr.

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ual seats .
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WARNING

Extract fuel from both chambers of fuel tank using fuel extractor
- VAS 5190A- or fuel extractor - VAS 5190- .
– Unclip cover -1- for left and right flange from retaining tabs
-arrows- using removal wedge - 3409- .
1. Fuel tank 25
n AG . Volkswage
– Unclip right sealing grommet
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– Disconnect connectors -1 and 2- as well as fuel line -3- from

flange.
– Open locking ring using wrench - T10202- .

– Carefully lift flange of fuel delivery unit -3-.

– Remove gasket -1- and carefully lift up the flange of the fuel
delivery unit slightly more.
Caution

body.
– Disconnect left connector -arrow-. Lay cover -1- with wiring

harness to one side.
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– Insert extraction hose of fuel extractor - VAS 5190A- or fuel
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If fuel tank needs only to be emptied, install fuel delivery unit
ole,
spec
again. ⇒ page 29 .
t to the co
Installing
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Specified torques
♦ ⇒ “2.1 Assembly overview - fuel delivery unit and fuel gauge
ss
sender”, page 28
o
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1. Fuel tank 27
2 Fuel delivery unit, fuel gauge sender

⇒ “2.1 Assembly overview - fuel delivery unit and fuel gauge
sender”, page 28
⇒ “2.2 Removing and installing fuel delivery unit, fuel
olks
gauge
wage send‐ es n
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⇒ “2.3 Removing and installing fuel gaugeut sender G ”,
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⇒ “2.4 Removing and installing fuel gauge sender 2 G169 ”, page
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2.1 Assembly overview - fuel delivery unit and fuel gauge sender
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1 - Fuel pump control unit -
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❑ Check with ⇒ Vehicle di‐
agnostic tester
rrectness of i
⇒ page 69
l purpos
2 - Electrical connector
❑ For fuel pump control
nform
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unit - J538- .
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❑ For fuel gauge sender -
G- and fuel gauge send‐
er 2 - G169-
5 - Locking ring
❑ Vehicles for North
American region: not in‐
stalled
❑ Remove and tighten
with wrench - T10202- .
❑ 110 Nm
6 - Flange
❑ Vehicles for North American region: not installed
7 - Seal
❑ Vehicles for North American region: not installed
❑ Renew after removal
❑ Install dry

8 - Fuel gauge sender 2 - G169-

❑ Vehicles for North American region: no assembly opening on left side of fuel tank; fuel gauge sender 2
cannot be removed
❑ Carry out electrical test with ⇒ Vehicle diagnostic tester
9 - Mounting with suction-jet pump
❑ No replacement part
❑ Welded to fuel tank
❑ Function ⇒ page 71
10 - Fuel gauge sender - G-
❑ Carry out electrical test with ⇒ Vehicle diagnostic tester
11 - Fuel delivery unit
❑ With fuel system pressurisation pump - G6- .
❑ With integrated fuel filter
❑ The fuel filter cannot be renewed individually
❑ Carry out electrical test on fuel pump with ⇒ Vehicle diagnostic tester
❑ After installing, fill vehicle with at least 5 litres of fuel.
12 - Seal
❑ Renew after removal
❑ Install dry
13 - Locking ring
❑ Remove and tighten with wrench - T10202- .
❑ 110 Nm
14 - Fuel line
❑ To engine
❑ Do not kink AG. Volkswagen AG d
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Installation position of fuel delivery unit

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• The arrow -3- on the fuel tank must line up with the mark -2-
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on the sealing flange -1-.

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2.2 Removing and installing fuel delivery

m
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unit, fuel gauge sender

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agen
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Removing
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Risk of fire due to escaping fuel.

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• The fuel tank must be only 3/4 full or less. This ensures
es, in part or in w
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that the fill level is below the flange of the fuel delivery unit.
rrectness of i

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– If necessary, empty fuel tank ⇒ page 22 . C py
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– Unclip cover -1- for sealing flange on right at retaining tabs

– Unclip sealing grommet -1- downwards from cover -2-.

– Push cover -2- back along wiring harness -3-.
WARNING

– Disconnect connectors -1 and 2- as well as fuel line -3- from

flange, and pull them off.
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WARNING
es, in part or in w
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Danger due to fuel running out of the fuel delivery unit.

♦ Place a cloth underneath to absorb fuel.
rrectness of i
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– Carefully lift flange of fuel delivery unit.

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2. Fuel delivery unit, fuel gauge sender 31

olkswagen AG
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Golf 2013 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf Variant
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Fuel supply system – petrol engines, Volkswagen R GmbH
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– Pull right flange -2- for a short distance out of the opening
ss
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the fuel tank.
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– Remove seal -1- at the opening in the fuel tank.
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– Release connector -arrow-. Disconnect connector -1- from
r
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– Carefully pull out fuel delivery unit -1- with fuel gauge sender
- G- -2- through opening in fuel tank by turning and tilting it as
required.
Note
♦ When removing the fuel delivery unit, ensure that the float arm
of the fuel gauge sender is not bent.
♦ If delivery unit is to be renewed, old delivery unit must be
drained before disposal.
♦ Observe environmental regulations for disposal.
♦ Check fuel tank for foreign bodies and dirt.

– Carefully pull out fuel lines through opening in fuel tank.

– Disconnect supply line for suction-jet pump -1- and supply line
-2-. To do this, press release mechanism on connection piece.
Installing
WARNING

AG. Volkswagen AG d
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DANGER! d by gu
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Risk of leaks. au ra
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♦ When sealing flange is inserted, ensure that seal is not

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♦ Push on supply line for suction-jet pump and supply line until
it engages audibly.
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♦ Insert new seal for fuel delivery unit dry into opening of fuel
l purpos
tank.
♦ When inserting fuel delivery unit, ensure that fuel gauge send‐
nf
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rm
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♦ Coat only inner side of seal with fuel.

o
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♦ Check connectors are secured properly by pulling.

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– Note installation position of flange when installing

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⇒ page 29 .
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Specified torques opyri
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♦ ⇒ “1.1 Assembly overview - fuel tank”, page 7
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♦ ⇒ “2.1 Assembly overview - fuel delivery unit and fuel gauge
sender”, page 28
2.3 Removing and installing fuel gauge

sender - G-
Removing
– Remove fuel delivery unit ⇒ page 29 .
– Disconnect connector -4- from right flange.

lkswage es n
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– Release retaining tabs at lugs -1 and 2- while pulling out fuel
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gauge sender - G- -3- upwards.
h re
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Installing
es, in part or in w
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– Insert fuel gauge sender - G- into guides on fuel delivery unit
rrectness of i
and press down until it engages.
l purpos
– Route and attach wires on fuel delivery unit.

– Install fuel delivery unit ⇒ page 29 .
nform
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2.4 Removing and installing fuel gauge
C py
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sender 2 - G169-
p by
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Prote AG.
Note
♦ On vehicles for the North American region there is no flange

fitted on the left side of the fuel tank.
♦ The fuel gauge sender 2 - G169- cannot be removed and in‐
stalled.


Removing
– Switch off ignition.
individual seats .
WARNING

♦ To prevent fuel escaping, the fuel tank must not be more
than 3/4 full when removing the fuel gauge sender.
– If necessary, empty fuel tank ⇒ page 22 .

– Unclip cover -1- for left flange at retaining tabs -arrows- using
removal wedge - 3409- .
AG. Volkswagen AG d
agen oes
olksw not
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– Separate electrical connector -arrow-. Lay cover -1- with wir‐

rm
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ing harness to one side.

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– Remove flange and seal from opening in fuel tank.

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– Grip through opening in fuel tank. Release connector catches

-arrow-, and disconnect connector -1-.
– Grasp through opening in fuel tank., release connector catch‐

es -arrows A-, and push connector -1- out of retainer
-arrow B-.
– Grasp through opening in fuel tank, release retaining tab at lug
-2-, and at the same time pull out fuel gauge sender 2 - G169-
upwards -arrow C-.
Installing
• ⇒ “2.1 Assembly overview - fuel delivery unit and fuel gauge
sender”, page 28
Note
♦ Note installation position of flange.

♦ Renew seal.
AG. Volkswagen AG d
♦ Ensure that the connectors are engaged correctly. lksw
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3 Plug-in connectors
⇒ “3.1 Separating plug-in connectors”, page 37
3.1 Separating plug-in connectors

♦ Lever - T10468-
Assignment of plug-in connectors
Note
. Volkswagen AG
gen AG d
♦ The plug-in connectors
Vol
ksfor
wa fuel, vacuum and breather
oes
not lines are
colour coded. There d b is either a coloured dot on the plug-in
y gu
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connector orthothe release button is of the respective colour
ri nte
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⇒ page 37s au. ra
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ce
♦ Plug-in connectors for fuel lines must engage »audibly« when

le
un
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joined.
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♦ Ensure plug-in connector is secured properly by pulling it.

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Colour assignment
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Plug-in connector Colour code on plug-in connector

es, in part or in w
t to the co
Fuel supply black

Fuel return line blue
rrectness of i
Breather White, beige

l purpos
Vacuum green
nform
mercia
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com
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WARNING
on in
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Wear protective goggles and protective clothing to avoid injury Cop py
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rig ht
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carefully opening the connection. Prote
cted AG.
agen
3. Plug-in connectors 37
Version 1
Plug-in connector with release buttons -arrows- on right and left:
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Counterhold at the coupling point for fuel -1- in the engine com‐
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spec
partment.
es, in part or in w
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– Insert lever - T10468- between heat shield and stop -arrow- of
fuel line -2- and counterhold.
rrectness of i
l purpos
nform
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Continuation for all coupling points on fuel system: Prote
cted AG.
agen
– Push plug-in connector -1- in -direction of arrow A-.

– Press and hold release buttons.
– Pull plug-in connector -1- off fuel line -2- in
-direction of arrow B-.
Note colour assignment during installation ⇒ page 37 .
Plug-in connectors for fuel lines must engage audibly when
joined.
– Ensure plug-in connector is secured properly by pulling it.

Version 2
Plug-in connector with pull-release mechanism -arrow-.
Open
– Push plug-in connector -1- in -direction of arrow A-.
– Pull pull-release mechanism -2- in -direction
en AG. V
oof
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wagen AB-.
G ag does
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-direction of arrow B-. orise nte
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Note colour assignmentssduring
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ce
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Plug-in connectors for fuel lines must engage »audibly« when

un
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Version 3
ss o
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Open
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– Press release button -arrow- and pull off plug-in connectors.

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Version 4
Plug-in connector with release button -arrows- on right and left:
Open
– Push plug-in connector in -direction of arrow A-.
– Press release buttons -arrows- and pull off plug-in connector.
joined.
3. Plug-in connectors 39
Version 5
Open
joined.
Version 6
Open
– Push plug-in connector -1- in -direction of arrow-, and hold it
in that position.
joined.
AG. Volkswagen AG d
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Version 7 by Vol not
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Plug-in connector -1- with
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4 Fuel filter
Pressure limiting valve and fuel filter are integrated in fuel delivery
unit and cannot be renewed individually ⇒ page 28 .
AG. Volkswagen AG d
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4. Fuel filter 41
5 Activated charcoal filter system

⇒ “5.1 Connection diagram - activated charcoal filter”,
page 42
⇒ “5.2 Assembly overview - activated charcoal filter system”, page
43
⇒ “5.3 Removing and installing activated charcoal filter”,
page 45
⇒ “5.4 Checking fuel tank breather”, page 49
⇒ “5.5 Checking fuel system for leaks”, page 54
5.1 Connection diagram - activated char‐

coal filter
⇒ “5.1.1 Connection diagram - activated charcoal filter system,
region North America”, page 42
5.1.1 Connection diagram - activated charcoal filter system, region North America
1 - Control unit for fuel tank

leak detection - J909-
❑ Version for region
“North America”
2 - Air filter
❑ For tank leak diagnostic
system
❑ Version for region
“North America”
3 - Tank pressure sensor - n AG. Volkswagen AG do
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❑ Version for region ir se tee
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“North America” aut or
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4 - Activated charcoal filter ce
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❑ Allocation ⇒ Electronic
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parts catalogue
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5 - Activated charcoal filter sol‐

wit
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enoid valve 1 - N80-

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t to the co
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5.2 Assembly overview s

-nactivated
wage
AG. Volkswagencharcoal
AG do
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filter systemed by olk ot g
V ua
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⇒ “5.2.1 Assembly overview
aut
ho - activated charcoal filter system”, eo
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page 43 ss c
ce
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un
⇒ “5.2.2 Assembly overview - activated charcoal filter system, re‐
pt
an
d
itte
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5.2.1 Assembly overview - activated charcoal filter system
ot
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1 - Breather line
es, in part or in w
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N80-
rrectness of i
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❑ Plug-in connectors must
nform
ercia
engage »audibly« when

m
joined
a
com
tion in
❑ Ensure plug-in connec‐
r
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tor is secured properly
thi
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by pulling it.
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❑ Checking breather
fo
en
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⇒ page 49
n
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❑ Connection diagram
t. C rig
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⇒ page 44 p by
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by lksw
❑ Disconnect plug-in con‐
cted agen
Prote AG.
nectors ⇒ page 37
2 - Bolt
❑ 20 Nm
3 - Activated charcoal filter
❑ Fitting location: On rear
right in wheel housing,
beneath wheel housing
liner.
❑ Checking breather
⇒ page 49
⇒ page 45
4 - Breather line
❑ To fuel tank
❑ Plug-in connectors must engage »audibly« when joined
❑ Ensure plug-in connector is secured properly by pulling it.
❑ Checking breather ⇒ page 49
❑ Connection diagram ⇒ page 44
❑ Disconnect plug-in connectors ⇒ page 37
5. Activated charcoal filter system 43

Connections on activated charcoal filter

1- -A- breather connection
2- -T- connection to fuel tank
3- -M- to activated charcoal filter solenoid valve 1 - N80- AG. Volkswagen AG d
agen oes
olksw not
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4- Cap d b ara
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5.2.2 Assembly overview - activated charcoal filter system, region North America
l purpos
nf
ercia
1 - Breather line
orm
m
❑ To fuel tank
atio
om
n in
or c
thi
te
sd
a
tors ⇒ page 37
iv
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2 - Breather line
f
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tors ⇒ page 37
3 - Air filter
❑ For tank leak diagnostic
system
❑ Fitting location: On rear
right in wheel housing,
beneath wheel housing
liner.
❑ Clipped onto activated
charcoal filter -item 13-
⇒ page 47
4 - Hose clamp
❑ Must be original equip‐
ment ⇒ Electronic Parts
Catalogue
5 - Hose
6 - Hose clamp
❑ Must be original equip‐
ment ⇒ Electronic Parts
Catalogue

7 - Tank pressure sensor - G400-

❑ Fitting location: On rear right in wheel housing, beneath wheel housing liner.
8 - Bolts
❑ Qty. 2
❑ 1.8 Nm
9 - Seal
❑ Insert in activated charcoal filter
❑ Renew after each removal ⇒ Electronic Parts Catalogue
10 - Control unit for fuel tank leak detection - J909-
❑ Fitting location: on fuel tank on right
11 - Bolts
❑ Qty. 2
❑ 3 Nm
12 - Bolt
❑ 20 Nm
13 - Activated charcoal filter
❑ Fitting location: On rear right in wheel housing, beneath wheel housing liner.
AG. Volkswagen AG d
❑ Removing and installing ⇒ page 46 lksw
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⇒ “5.3.3 Removing and installing air filter for activated charcoal t to the co
filter system, region North America”, page 47
⇒ “5.3.4 Removing and installing tank pressure sensor G400 ,
rrectness of i

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⇒ “5.3.5 Removing and installing control unit for fuel tank leak
detection J909 , region North America”, page 48
nf
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⇒ “5.3.6 Checking fuel system for leaks, region North America”,

or
page 49
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5.3.1 Removing and installing activated char‐

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– Remove rear right wheel housing liner ⇒ General body re‐ Prote AG.
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - rear wheel housing liner .

– Disconnect breather lines -1- and -2- from activated charcoal

filter.
– Unclip breather lines from retainer -arrows-.
– Unscrew bolt -1-.

– Press in locking device -3- using screwdriver.
– Pull activated charcoal filter -2- downwards in
-direction of arrow- out of mounting.
Installing
Specified torques
♦ ⇒ “5.2 Assembly overview - activated charcoal filter system”,
page 43
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– Heed the safety precautions ⇒ page 1 .

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– Pull breather lines -3- off activated charcoal filter. To do so,

disconnect plug-in connectors ⇒ page 37 .
– Pull activated charcoal filter -4- downwards out of mounting,
and remove it.
Installing
Specified torques
♦ ⇒ “5.2.2 Assembly overview - activated charcoal filter system,
5.3.3 Removing and installing air filter for ac‐

tivated charcoal filter system, region
North America
♦ Spring-type clip pliers - VAS 6362-
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Removing
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– Remove activated charcoal filter ⇒ page 46 .

– Unclip locking lugs to release air filter -1- from activated char‐
rrectness of i
coal filter.
l purpos
– Disconnect breather hose -2-. To do this, loosen hose clip

-3- using hose clip pliers - VAS 6362- .
nform
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– Remove air filter -1-.

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Install in reverse order of removal.

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5.3.4 Removing and installing tank pressure

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♦ Spring-type clip pliers - VAS 6362-
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– Disconnect breather hose -3-. To do this, loosen hose clip
hole
spec
-2- using hose clip pliers - VAS 6362- .
es, in part or in w
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– Unscrew bolts -4-.
– Pull off tank pressure sensor - G400- -1- in direction of
rrectness of i
-arrow-.
Installing
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Renew gasket after each removal ⇒ Electronic Parts Catalogue .

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5.3.5 Removing and installing control unit for
AG.
fuel tank leak detection - J909- , region

North America
Removing
– Detach bracket -1- for control unit for fuel tank leak detection
- J909- from mounting -2- on fuel tank.
– To do this, grasp control unit for fuel tank leak detection - J909-
-3- with your hand, and carefully and alternately release it from
locking devices in direction of -arrow-.

– Remove control unit -2- downwards together with bracket -4-.

– Unscrew bolts -3- and -5-, and remove control unit for fuel tank
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5.3.6 Checking fuel system for leaks, region
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♦ The operating principle of the tank leak diagnostic system is
based on the fact that a vacuum develops naturally in the fuel
rrectness of i
system as the temperature of the fuel in the tank decreases.
l purpos
♦ Thus, the tank pressure sensor - G400- -item 3- detects the

vacuum in the breather line -4- near the activated charcoal
filter -1-. Since the control unit for fuel tank leak detection -
nform
ercia
J909- -item 7- is mounted directly on the fuel tank wall -6-, it

is capable of measuring the temperature in the fuel tank. The
m
a
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system is deemed leak-free if a vacuum of 2.5 mbar is meas‐
ion in
ured. If no vacuum develops, there is a leak in the fuel system,
r
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Fuel supply system – petrol engines, Volkswagen
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equipment required
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♦ Engine bung set - VAS 6122-

♦ Hand operated vacuum pump - VAS 6213-
♦ Adapter set - VAS 6550-
Test sequence
Checking activated charcoal filter system solenoid valve 1 - N80- :
– Read event memory ⇒ Vehicle diagnostic tester.

– Release and pull off breather line -1-. Separate plug-in con‐
nectors ⇒ page 37 .
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– Using a connecting nipple - VAS 6213- and a standard hose,
t to the co
connect hand vacuum pump - VAS 6550/3-1- to line leading
to active charcoal filter system solenoid valve 1 - N80- .
rrectness o
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– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
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sition -A- for “vacuum”.

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uum must build up. cop Vo
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If vacuum does not build up:
AG.
– Check line leading to activated charcoal filter solenoid valve 1

- N80- for leaks and damage.
If no fault is detected:
Activated charcoal filter solenoid valve 1 - N80- OK.
If vacuum builds up:

Activated charcoal filter solenoid valve 1 - N80- OK:
– Release and pull off breather line -1-. Separate plug-in con‐
nectors ⇒ page 37 .

– Connect hand vacuum pump - VAS 6213- with adapter set - agen
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– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -A- for “vacuum”.
rrectne
– Operate hand vacuum pump - VAS 6213- several times. There
must be no development of vacuum.
ss o
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f inform
mer
atio
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
om
overview - rear wheel housing liner .
n
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– Check breather connection -A- on activated charcoal filter for
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– Repeat check.
– Pull breather lines -2- on connection -T- off activated charcoal

filter. Separate plug-in connectors ⇒ page 37 .

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– Seal connection -3- using suitable workshop equipment.
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rrectness
– Seal connection -A- of activated charcoal filter -2- with a suit‐
o
cial p
f
able plug from engine bung set - VAS 6122- -1-.
inform
mer
atio
uum must build up.
om
n
c
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rig ht
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– Pull breather lines -2- on connection -M- off activated charcoal
filter -1-. Separate plug-in connectors ⇒ page 37 .
– Connect hand vacuum pump - VAS 6213- to connection -M-

of activated charcoal filter -1- by means of commercially avail‐
able hose -3-.
• Connection -2- is sealed using suitable workshop equipment.
• Connection -A- is sealed with suitable plug from engine bung
set - VAS 6122- ⇒ page 53 .
uum must build up.

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– Check line between coupling point -1- in engine compartment
ility
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and connection -M- on activated charcoal filter. Renew, if nec‐
wit
, is n
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spec
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– Renew activated charcoal filter ⇒ page 45 .
If vacuum builds up and line is OK:
rrectness of i
– Check line ⇒ Item 4 (page 43) between connection -T- on ac‐
tivated charcoal filter and fuel tank. Renew, if necessary.
Line to fuel tank is OK: l purpos
nform
ercia
– Check fuel tank for leaks.
m
at
– Check cap ⇒ Item 14 (page 9) on fuel filler neck.
om
ion
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If vacuum builds up and lines are OK, proceed as follows:

o
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Check activated charcoal filter solenoid valve 1 - N80- . To do this,

p
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proceed as follows ⇒ page 50 .

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5.5 Checking fuel system for leaks
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♦ The operating principle of the tank leak diagnostic system is Prote
cted AG.
agen
based on the fact that a vacuum develops naturally in the fuel
system as the temperature of the fuel in the tank decreases.
♦ Thus, the tank pressure sensor - G400- -3- detects the vacuum
in the breather line -4- near the activated charcoal filter -1-.
Since the control unit for fuel tank leak detection - J909- -7- is
mounted directly on the fuel tank wall -6-, it is capable of
measuring the temperature in the fuel tank. The system is
deemed leak-free if a vacuum of 2.5 mbar is measured. If no
vacuum develops, there is a leak in the fuel system, and an
entry will be made in the event memory of the engine control
unit.
2 - Signal line to engine control unit - J623-
5 - Breather line to engine

6 Accelerator pedal
⇒ “6.1 Assembly overview - accelerator module”, page 55
⇒ “6.2 Removing and installing accelerator pedal module GX2 ”,
page 56
6.1 Assembly overview - accelerator module
1 - Bolt
❑ 6 Nm
3 - Gas pedal module - GX2-
❑ Includes
Acceleration pedal posi‐
tion sender - G79-
Accelerator position
sender 2 - G185-
⇒ page 56
AG. Volkswagen AG d
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6. Accelerator pedal 55
6.2 Removing and installing accelerator

pedal module - GX2-
Removing
– Fold back floor covering -1- in -direction of arrow-.

– Remove accelerator pedal module - GX2- -3-.
Installing
Install in reverse order of removal, observing the following: AG. Volkswagen AG d
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♦ ⇒ “6.1 Assembly overview - accelerator module”,
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⇒ “7.1 Checking fuel system pressurisation pump G6 ”,
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⇒ “7.2 Removing and installing fuel pump control unit J538 ”, page
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, is n
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7.1 Checking fuel system pressurisation
spec
es, in part or in w
pump - G6-
t to the co
⇒ “7.1.1 Checking fuel pressure”, page 57
rrectness of i
⇒ “7.1.2 Checking holding pressure”, page 61
l purpos
⇒ “7.1.3 Checking fuel delivery rate”, page 65
7.1.1 Checking fuel pressure
nform
mercia
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equipment required
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♦ Pressure gauge - VAS 6550-
♦ Connector cable - VAS 6550/3-3-
7. Fuel pump 57
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♦ Connector cable - VAS
ss 6550/3-4-
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♦ Vehicle diagnostic tester
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Condition:
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WARNING
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– Pull off supply line -1-. Separate plug-in connectors
en
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t.
⇒ page 37 .
yi Co
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– Collect escaping fuel with a cleaning cloth. gh ht
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Prote AG.
– Connect hose - VAS 6550- to connection -A- of pressure tester

- VAS 6550/1- .
– Connect hose - VAS 6550/1- to fuel supply line -1- leading to
engine.
– Connect hose - VAS 6550/2- to connection -B- of pressure
tester - VAS 6550- .
– Use hose - VAS 6550- to connect fuel line leading to fuel tank
with pressure tester - VAS 6550/2- .
– Ensure plug-in connectors are secure properly by pulling.

– Ensure that drain tap -C- on pressure tester -1- is closed.

– Shut-off valves -A- and -B- on pressure tester -1- are open.
– Connect vehicle diagnostic tester .
– Select final control diagnosis for fuel pump in vehicle self-di‐
agnosis program.
Note
♦ The fuel pump is now actuated to build up fuel pressure.

♦ If the final control diagnosis is to be carried out several times
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.
– Read off fuel pressure on pressure gauge.

• Specification: 4.0 … 7.0 bar
If fuel pressure is OK, check holding pressure ⇒ page 61 .
If the specification is exceeded:
– Pressure limiting valve in fuel delivery unit is defective.
– Renew fuel delivery unit ⇒ page 29 .
If specification is not obtained
Proceed as follows to check fuel pressure at fuel delivery unit:
ual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- . gen AG
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7. Fuel pump 59
– Push tab -2- up in direction of -arrow A-. To do this, reach in

with your finger between the floor plate and fuel tank.
– Place fuel pump control unit - J538- (with connector still con‐
nected) to one side.
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– Pull fuel line -3- off flange.
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Note
Do not disconnect connectors -1 and 2-. rrectness o

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– Connect pressure tester - VAS 6550- with hose - VAS

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– Connect hose - VAS 6550/3-3- between pressure tester - VAS
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– Repeat final control diagnosis to build up fuel pressure.
If reading matches specification:
– Check fuel lines for possible restrictions (kinks) or blockages.
– Check fuel line for leaks and damage.
– Remove fuel delivery unit ⇒ page 29 and check for contami‐
nation.
– Check that all hoses are connected.
– Check fuel lines for leaks and damage.
If no fault is found:
– Fuel pump is defective; renew fuel delivery unit ⇒ page 29 .
7.1.2 Checking holding pressure
Special tools and workshop agen

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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Fuel pump 61
♦ Pressure gauge - VAS 6550-

♦ Vehicle diagnostic tester
• Fuel pressure OK and pressure tester - VAS 6550- connected.
Check fuel pressure ⇒ page 57 .
– Connect adapter - VAS 6550/2- between fuel line from fuel
tank to shut-off tap -B- of pressure tester - VAS 6550- .
– Connect adapter - VAS 6550/1- between fuel line to engine
-1- and shut-off tap -A- of pressure tester - VAS 6550-
wage
n. AG. Volkswagen AG do
e
olks s no
yV t gu
Test sequence edb ara
ris nte
– Connect vehicle diagnostic tester . tho eo
au ra
c
ss
– Select final control diagnosis for fuel pump in vehicle self-di‐
ce
e
nl
pt
agnosis program.
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
♦ The fuel pump is now actuated to build up fuel pressure.
spec
es, in part or in w
♦ If the final control diagnosis is to be carried out several times
t to the co
in succession, it may be necessary to start the engine briefly
before repeating the final control diagnosis.
rrectness of i
– Read off fuel pressure on pressure gauge.
l purpos
• Specification: ≥ 4.0 bar
nf
ercia
– End self-diagnosis, and switch off ignition. orm

m
– Observe pressure drop on pressure gauge. Pressure must re‐

atio
m
main above 3.0 bar for 10 minutes.

o
n in
or c
thi
e
If the pressure drops:

t
sd
iva
o
r
rp
cu
– Check all fuel lines for leaks and damage.

o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

If no fault is detected:
– Actuate fuel pump with final control diagnosis .to build up fuel
AG Volkswagen AG d
pressure. kswagen oes
n ol ot g
yV ua
– After pressure has built up, close ed shut-off valve -A- of pressure
b ran
ris
tester immediately. Lever uisthothen at right angle to direction of tee
or
flow. ss a ac
ce
e
If the pressure now drops (leak on fuel tank side):

nl
pt
du
an
itte
y li
Proceed as follows to check residual pressure on fuel delivery unit
erm
ab
⇒ page 63 .
ility
ot p
wit
, is n
If the pressure does not drop now (leak on engine side):
h re
hole
spec
es, in part or in w
Note
t to the co
Search for leak on engine side. Repeat holding pressure check.
This time, close shut-off valve -B- to check whether leak actually
rrectness of i
is on engine side.
l purpos
– If there is a leak on engine side, carry out external check of

fuel pipes and high-pressure pump for leaks.
nform
mercia
If no fault can be determined, check the injectors for leaks:
at
om
ion
c
– Remove spark plugs.
in t
or
his
ate
– Open shut-off valves -A- and -B-. Actuate fuel pump with final
do
priv
c
control diagnosis.
um
for
en
ng
t.
– Check through spark plug holes whether fuel has collected on
yi Co
op
piston crown due to a leaking injector.
C py
t. rig
gh ht
yri by
Checking residual pressure on fuel delivery unit:
op Vo
by c lksw
cted agen
Prote AG.
ual seats .
– Unclip cover -1- for flange at retaining tabs -arrows-, using re‐
moval wedge - 3409- .
7. Fuel pump 63

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
– Push tab -2- up in direction of -arrow A-. To do this,
ss areach in ra
c
with your finger between the floor plate and fuel tank.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Place fuel pump control unit - J538- (with connector still con‐
t to the co
nected) to one side.
rrectness of i
WARNING
l purpos

nform
ercia

m
at
om
ion
c
in t
or
his
e

at
do
priv
cum
for
en
ng
t.
yi Co
op
– Pull fuel line -3- off flange. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
Note
agen
Prote AG.
Do not disconnect connectors -1 and 2-.

AG. Volkswagen AG d
– Connect pressure tester - VAS 6550- to fuel deliverywagunit
en -1- oes
olks not
by means of hose - VAS 6550/3-4- . db
y V gu
ara
e nte
ris
– Connect pressure tester - VAS 6550/3-3-
ut to fuel line
ho -2- by eo
ra
means of hose - VAS 6550- . ss
a c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
– Actuate fuel pump with final control diagnosis to build up fuel
r
rp
cum
pressure.
fo
en
ng
t.
yi Co
– After pressure has built up, close shut-off tap -B- of pressure . Cop py
tester immediately. Lever is then at right angle to direction of
t rig
gh ht
yri by
flow. cop Vo
by lksw
cted agen
Prote
– Repeat holding pressure check ⇒ page 62 .
AG.
If pressure no longer drops:

– Check fuel line for leaks.
If the pressure drops again:
– Open fuel delivery unit ⇒ page 29 .
– Check that all hose connections are connected.
If no fault is found:
– Pressure retention valve in fuel delivery unit is defective; re‐
new fuel delivery unit ⇒ page 29 .
7.1.3 Checking fuel delivery rate
7. Fuel pump 65

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Remote control for V.A.G 1348 - V.A.G 1348/3A- with adapter

cable -V.A.G 1348/3-3-
nform
ercia
♦ Pressure tester - VAS 6550- with hose - VAS 6550/2-

m
a
com
tio
♦ Pressure regulating valve - VAS 6550/4- (not illustrated)

n in
r
te o
thi
♦ Adapter set - V.A.G 1594C-

s
iva
do
r
rp
Procedure
um
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Checking fuel delivery rate in engine compartment, quick test: cted agen
Prote AG.
Note
The fuel delivery rate must first be checked in the engine com‐
partment with the help of the function “Checking fuel delivery rate,
quick test”. If the minimum delivery rate is not achieved, a second
measurement must be carried out at the flange of the fuel delivery
unit.

– Connect vehicle diagnostic tester .

– Start Guided Functions.
– Select "Check fuel delivery rate, quick test".
– Follow instructions on vehicle diagnostic tester .
– Check fuel delivery rate, repeat quick test.
If reading matches specification:
– Check fuel tank breather ⇒ page 49 .
AG. Volkswagen AG d
agen
If no fault is found: Volksw
oes
not
gu
d by ara
Proceed as followsorito
s check fuel delivery rate at fuel delivery
e nunit:
tee
h
ut or
Checking fuelssdelivery rate on fuel delivery unit:
a ac ce
e
nl
pt
du
an
WARNING
itte
y li
erm
ab
ility
ot p

wit
, is n
h re

hole
spec

es, in part or in w
t to the co
rrectness of i
l purpos
– Pull off supply line -1-. Separate plug-in connectors

⇒ page 37 .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
7. Fuel pump 67
– Using hose - VAS 6550- , connect pressure tester - VAS

6550/2- to fuel supply line.
– Fit pressure regulator valve - VAS 6550/4- , and hold hose in
a fuel resistant measuring container.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
– Switch on pressure tester - VAS s6550-
au -item 1- by pressing ac
On/Off button. s
ce
e
nl
pt
du
an
itte
y li
DANGER!
erm
ab
ility
ot p
wit
, is n
h re
hole
♦ Ensure that drain tap -C- is closed.
spec
es, in part or in w
♦ The lever is at right angle to direction of flow.
t to the co
– Open shut-off taps -A and B-.
rrectness of i
• The handles point in direction of flow.
l purpos

nform
ercia
ual seats .
m
at
om
ion
c

in t
or
-arrows- using removal wedge - 3409- . his

ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disconnect connector from right flange -1-, releasing the con‐

nector catches to do so.

– Connect remote control for V.A.G 1348 - V.A.G 1348/3A- with

adapter cable -V.A.G 1348/3-3- to contact -1- using an auxili‐
ary cable from auxiliary measuring set - V.A.G 1594C- .
– Tape off second connector contact of the adapter cable -V.A.G
1348/3-3- with insulating tape -arrow- to prevent short circuit.
– Connect contact -5- to vehicle body (earth) -A- using a test
lead from auxiliary measuring set - V.A.G 1594C- .
– Connect crocodile clip to positive battery terminal -item B-.
Note
Before measuring the fuel delivery rate, a counterpressure must

be built up in the fuel line against which the fuel pump has to work
during measurement. This counterpressure can be built up using
the pressure regulator valve - VAS 6550/4- as follows:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut
– Build up a counterpressure in fuel system.
ss a To do this, press ra
c
button on remote control, and turn adjuster screw -1- at pres‐
ce
le
un
sure regulator valve - VAS 6550/4- until the correct counter‐
pt
an
d
pressure has been attained.

itte
y li
erm
ab
• Specification: 4.0 bar
ility
ot p
wit
is n
– Do not turn adjuster screw -1- anymore from this point on.
h re
ole,
spec
– Drain measuring container.
t to the co
– Press remote control button for 15 seconds.
rrectnes
– Compare amount of fuel delivered with minimum delivery
s o
shown in diagram (cm3/15 s).
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
The voltage at he fuel pump with engine stationary and pump

t
sd
va
running is approx. 2 volts less than the battery voltage.

i
o
pr
cum
r
fo
en
ng
t.
yi
If the minimum delivery rate is not achieved, the following faults
Co
Cop py
may have occurred: ht. rig
rig ht
py by
o Vo
♦ Fuel lines have been crushed. by c lksw
cted agen
Prote AG.
♦ Fuel pressure regulator defective.
♦ Fuel pump defective.
♦ Fuel filter in fuel delivery unit blocked.
– Push on fuel line until it engages audibly.
– Press on fuel line again, and pull it to check that plug-in con‐
nector is correctly engaged.
7.2 Removing and installing fuel pump con‐

trol unit - J538-
7. Fuel pump 69
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Removing
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
individual seats .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.

Fuel supply system – petrol engines,AGVolkswagen
. Volkswagen A R GmbH - Edition 07.2017
n G do
wage es n
V olks ot g
– Push tab -2- up in direction of -arrow A-. Toeddo by this, reach in ua
ran
with your finger between the floor plate and oris fuel tank. tee
th or
au ac
– At the same time, carefully pull fuel pump
ss control unit - J538-
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Installing
hole
spec
Install in reverse order of removal, observing the following: es, in part or in w
t to the co
– Connect wiring harness to fuel pump control unit - J538- .
– Check if connector is secured properly by pulling it.
rrectness of i
– Insert fuel pump control unit - J538- into mounting bracket on
l purpos
fuel tank and push it in until it audibly engages.

– Pull on fuel pump control unit - J538- to make sure that it is
nform
ercia
properly secured.
m
at
om
io
7.3 Removing and installing suction-jet
n
c
in t
or
pump
his
ate
do
priv
cum
for
en
ng
t.
yi
Note
Co
Cop py
ht. rig
rig ht
On vehicles for the North American region there is no flange fitted
py by
co Vo
by lksw
on the left side of the fuel tank. Prote
cted AG.
agen
7. Fuel pump 71
AG. Volkswagen AG d
On vehicles with four-wheel drive the fuel tank is divided into a wage
n oes
olks not
left and a right chamber. A suction-jet pump -2- is used for deliv‐ by
V gu
ara
ering fuel from the left fuel tank chamber to the baffle housing ed
oris of nte
the fuel delivery unit -1- on the right. au
th eo
ra
ss c
Function of suction-jet pump
ce
le
un
pt
an
d
The suction-jet pump operates according to the principle of fluid
itte
y li
entrainment: the stream of fuel from the electrical fuel pump is
rm
ab
pe
ility
passed through a nozzle in the suction-jet pump, and is thus ac‐
ot
wit
celerated. The accelerated stream of fuel draws off the surround‐
, is n
h re
ing fuel and delivers it to the baffle housing of the fuel delivery
hole
unit.
spec
es, in part or in w
t to the co
Faults caused by defective suction-jet pump
Caution
rrectness of i
l purpos
Risk of breakdown due to defective suction-jet pump.

♦ If the suction-jet pump is defective, the engine can stop
nform
ercia
due to fuel starvation when the tank is still 1/4 full.

m
a
com
tion in
r
If the suction-jet pump does not work, approx. 15 litres of fuel (1/
te o
thi
s
4 of tank capacity) remain in the left chamber of the fuel tank and
iva
do
r
rp
c
cannot be extracted by the fuel delivery unit.
um
fo
en
ng
t.
yi
If the engine stops due to fuel starvation with the tank filled up to
Co
op py
about 1/4, proceed as follows:
t. C rig
gh ht
pyri by
Vo
co
– Check fuel pump with ⇒ Vehicle diagnostic tester.
by lksw
cted agen
Prote AG.
If fuel pump is OK, but no fuel is delivered:
– Refill fuel tank with approx. 5 litres of fuel.
– Start engine.
If engine starts OK now:
– The suction-jet pump cannot be renewed individually. Renew
fuel tank ⇒ page 11 .

Fuel Supply System ΓÇô Petrol Engines Volkswagen R GmbH (1)

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Service

Golf Variant 2017 ➤

Service Department. Technical Information

All rights reserved.

Copyright © 2017 Volkswagen AG, Wolfsburg D4B803919C8

1.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.1 Separating plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.1 Connection diagram - activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.2 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

⇒ “1.3 Safety measures when working on vehicles with a start/

stop system”, page 2

– To release pressure, wrap a clean cloth around the connection

and carefully loosen the connection.

– Deactivate start/stop system by switching off the ignition.

2 Rep. gr.00 - Technical data

2.1 Engine number/engine data

Codes CJXD CJXG DJHA

Displacement l 1.984 1.984 1.984

Power kW at rpm 213/5400 to 6500 228/5800 to 6500 228/5500 to 6500

Torque Nm at rpm 380/1850 to 5100 380/1850 to 5700 400/2000 to 6500

Bore ∅ mm 82.5 82.5 82.5

Stroke mm 92.8 92.8 92.8

Compression ratio 9.3:1 9.3:1 9.3:1

Ignition/injection system FSI FSI FSI

Exhaust gas recirculation No No No

Exhaust gas temperature regulation No No No

Charging Exhaust turbocharg‐ Exhaust turbocharg‐ Exhaust turbocharg‐

Knock control yes yes yes

Intercooler yes yes yes

Lambda regulation yes yes yes

Codes CJXD CJXG DJHA

Codes DJHB DJJA DLRA

Ignition/injection system FSI FSI FSI

Exhaust gas temperature regulation No No No

Camshaft timing adjustment yes yes yes

Secondary air system No No No

Valves per cylinder 4 4 4

4 Rep. gr.00 - Technical data

3.1 Rules for cleanliness when working on

♦ Place removed parts on a clean surface and cover them over.

♦ If repair work cannot be performed immediately, carefully cov‐

aging until immediately before installing. Do not use parts that

♦ Protect disconnected electrical connectors from dirt and water,

4.1 Routing and attachment of lines

they can be re-installed in the original positions and correctly

connected. Where necessary, make sketches or take photo‐

4.2 General repair instructions

haust gas extraction system must be laid near to the assembly

♦ If no exhaust gas extraction system is available, a radial fan

with a displacement greater than 15 m3/h can be used provid‐

ing that motor is not in air flow.

♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

6 Rep. gr.00 - Technical data

20 – Fuel supply system

1.1 Assembly overview - fuel tank

1.1.1 Assembly overview - fuel tank

Risk of explosion of fuel tank. If a new or completely empty fuel

❑ For heat shield

❑ For fuel tank

9 - Securing strap on right

❑ Clipped onto fuel tank.