Volkswagen 2015 Golf GTI Operating instructions

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Repair Manual
Golf 2015 ➤
Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines
Engine ID CNT
A
CXB
A
CNS
A
CXB
B
CNS
B
CXC
A
CXC
B
Edition 01.2016
Service
Service Department. Technical Information
ProCarManuals.com

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List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
20 - Fuel Supply
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D4B80416623
ProCarManuals.com

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Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Precautions when Working on Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety Precautions when Working on Vehicles with Start/Stop System . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine Number/Engine Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Parking/Auxiliary Heater and Fuel System Clean Working Conditions . . . . . . . . . . . . . . . . 4
4 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Wire Routing and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Overview - Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Fuel Tank, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Fuel Tank, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2 Fuel Delivery Unit/Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Overview - Fuel Delivery Unit/Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.2 Fuel Delivery Unit/Fuel Level Sensor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 52
2.3 Fuel Level Sensor G , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.1 Fuel Lines, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4 Connector Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.1 Connector Couplings, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6 EVAP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.1 Connection Diagram - EVAP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.2 Overview - EVAP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.3 EVAP Canister, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.4 Fuel Tank, Checking Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.5 Fuel System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7 Accelerator Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.1 Overview - Accelerator Pedal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.2 Accelerator Pedal Position Sensors G79 / G185 , Removing and Installing . . . . . . . . . . . . 80
8 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1 Transfer Fuel Pump G6 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.2 Fuel Pump Control Module J538 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 116
9 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
9.1 Fuel Tank Pressure Sensor G400 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 119
9.2 Fuel Tank Leak Detection Control Module J909 , Removing and Installing . . . . . . . . . . . . 120
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
11 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
Contents i
ProCarManuals.com

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Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
ii Contents
ProCarManuals.com

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00 – General, Technical Data
1 Safety Precautions
(Edition 01.2016)
⇒ 1.1 Safety Precautions when Working on Fuel Supply System,
page 1
⇒ 1.2 Safety Precautions during Road Test with Testing Equip‐
ment, page 1
⇒ 1.3 Safety Precautions when Working on Vehicles with Start/
Stop System, page 2
1.1 Safety Precautions when Working on
Fuel Supply System
Caution
There is a risk of injury due to the fuel being under pressure.
The fuel system is under pressure. Injuries are possible from
fuel spraying out.
Before opening the fuel system:
– Wear protective eyewear.
– Wear safety gloves.
– Reduce the pressure: place clean cloths around the connec‐
tion point and carefully open the connection point.
Procedure for reducing the high fuel pressure. Refer to ⇒ Rep.
Gr. 24 ; Fuel Injection System; High Fuel Pressure, Reducing .
Caution
Risk of a fire due to leaking fuel.
When the battery is connected, the door contact switch acti‐
vates the fuel pump when opening the driver door. Leaking fuel
can ignite and start a fire.
– Before opening the fuel system, interrupt the power supply to
the fuel pump.
1.2 Safety Precautions during Road Test
with Testing Equipment
WARNING
There is a risk of injury caused by unsecured testing equip‐
ment.
If the front passenger airbag deploys during an accident, un‐
secured testing equipment becomes a dangerous projectile.
– Secure the testing equipment on the rear seat.
or
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
1. Safety Precautions 1
ProCarManuals.com

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– Have a second technician operate the testing equipment on
the rear seat.
1.3 Safety Precautions when Working on
Vehicles with Start/Stop System
WARNING
There is a risk of injury due to the engine starting unexpectedly.
The engine can start unexpectedly on vehicles with an activa‐
ted Start/Stop System. A message in the instrument cluster
indicates whether the Start/Stop System is activated.
– Deactivate the Start/Stop System: switch off the ignition.
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
2 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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2 Identification
⇒ 2.1 Engine Number/Engine Characteristics, page 3
2.1 Engine Number/Engine Characteristics
Codes CXBA CXBB CNSA CNSB
Emissions values SULEV SULEV SULEV SULEV
Displace‐
ment
liter 1.8 1.8 1.8 1.8
Output kW 125 125 125 125
RON 95 unleaded 95 unleaded 95 unleaded 95 unleaded
Codes CXCA CNTA CXCB
Emissions values SULEV SULEV SULEV
Displacement liters 2.0 2.0 2.0
Output kW 162 155 162
Research Octane Number
(RON)
95 unleaded 95 unleaded 95 unleaded1
1) Starting 2016 91 RON
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
2. Identification 3
ProCarManuals.com

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3 General Information
⇒ 3.1 Parking/Auxiliary Heater and Fuel System Clean Working
Conditions, page 4
3.1 Parking/Auxiliary Heater and Fuel Sys‐
tem Clean Working Conditions
Special tools and workshop equipment required
♦ Engine Bung Set - VAS6122-
Follow these five rules when working on the fuel supply/injector
system:
♦ Thoroughly clean the connecting points and the surrounding
area before loosening.
♦ Place the removed parts on a clean surface and cover them.
Only use lint-free cloths!
♦ Carefully cover or seal opened components if the repair will
not be done immediately.
♦ Only install clean parts: remove replacement parts from the
packaging immediately prior to installation. Do not use parts
that have been stored loose (for example, in tool boxes etc.).
♦ When the system is open: do not work with compressed air.
♦ Do not move vehicle.
♦ Seal off any open lines and connections immediately with
plugs, for example, take from -VAS6122- .
♦ Protect the disconnected connectors from dirt and moisture
and only connect when they are dry.
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
4 Rep. Gr.00 - General, Technical Data
ProCarManuals.com

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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 .
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
4. Repair Information 5
ProCarManuals.com

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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 .
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
6 Rep. Gr.20 - Fuel Supply
ProCarManuals.com

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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 .
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
1. Fuel Tank 7
ProCarManuals.com

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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 .
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
8 Rep. Gr.20 - Fuel Supply
ProCarManuals.com

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7 - Fuel Tank
❑ Removing and Installing. Refer to
⇒ 1.2.3 Fuel Tank, Removing and Installing, Vehicles with Torsion Beam Rear Suspension,
page 23 .
8 - Heat Shield
❑ For the fuel tank
9 - Locking Plate
❑ Quantity: 4
❑ For the heat shield
10 - Mounting Strap
❑ Pay attention to proper seating
❑ Mark the direction of travel during removal
11 - Bolt
❑ 20 Nm + 90°
❑ Replace after removing.
12 - 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 .
13 - Bracket
❑ For the Metering Pump - V54-
❑ Make sure the Metering Pump - V54- is seated correctly in the bracket
14 - Fuel Supply Line
❑ 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 .
15 - Fuel Line
❑ For vehicles with a parking heater, from the Metering Pump - V54- for the parking heater
❑ Do not kink
❑ Installation position. Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. 82 ; Component
Location Overview - Fuel Supply .
❑ Check the fit by pulling on it.
16 - Metering Pump - V54-
❑ For vehicles with parking heater
❑ Secured on the fuel tank ⇒ Item 13 (page 9) .
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
1. Fuel Tank 9
ProCarManuals.com

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1.1.3 Overview - Fuel Tank, Vehicles with Fuel Tank Leak Detection
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 - Fuel Supply Line
❑ 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 Cou‐
plings, Disconnecting,
page 62 .
5 - Locking Ring
❑ 110 Nm
6 - Seal
❑ Replace
❑ Install dry
7 - 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 Installing, page 52
❑ With Fuel Level Sensor - G-
❑ Fuel Level Sensor - G- , Removing and Installing. Refer to
⇒ 2.3 Fuel Level Sensor G , Removing and Installing, page 56 .
❑ With the Transfer Fuel Pump - G6-
❑ Transfer Fuel Pump - G6- , Checking. Refer to ⇒ 8 Fuel Pump, page 81 .
8 - Fuel Tank
❑ Removing and Installing. Refer to
⇒ 1.2.3 Fuel Tank, Removing and Installing, Vehicles with Torsion Beam Rear Suspension,
page 23 .
9 - Bolt
❑ 20 Nm +90°
❑ Replace after removing.
10 - Heat Shield
❑ For the fuel tank
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
10 Rep. Gr.20 - Fuel Supply
ProCarManuals.com

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11 - Metal Nut
❑ For the heat shield
12 - Bolt
❑ 20 Nm +90°
❑ Replace after removing.
13 - Mounting Strap
❑ Pay attention to proper seating
❑ Mark the direction of travel during removal
14 - Bleeder Line
❑ To the EVAP Canister Purge Regulator Valve 1 - N80-
15 - Bracket
❑ For Fuel Tank Leak Detection Control Module - J909-
16 - Connection Cable
❑ For Fuel Tank Leak Detection Control Module - J909-
17 - Fuel Tank Leak Detection Control Module - J909-
18 - Protective Plate
19 - Rivets
❑ For securing the protective plate
1.2 Fuel Tank, Removing and Installing
⇒ 1.2.1 Fuel Tank, Removing and Installing, Vehicles with Multi-
Link Rear Axle, page 11
⇒ 1.2.2 Fuel Tank, Removing and Installing, Vehicles with Multi-
Link Rear Axle and Leak Detection-Fuel Tank, page 17
⇒ 1.2.3 Fuel Tank, Removing and Installing, Vehicles with Tor‐
sion Beam Rear Suspension, page 23
⇒ 1.2.4 Fuel Tank, Removing and Installing, Vehicles with Tor‐
sion Beam Rear Suspension and Engine Code CWVA,
page 29
1.2.1 Fuel Tank, Removing and Installing, Ve‐
hicles with Multi-Link Rear Axle
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Trim Removal Wedge - 3409-
♦ Engine and Gearbox Jack - VAS6931-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
Removing
– Observe the safety instructions. Refer to
⇒ 1 Safety Precautions, page 1 .
– Follow the guidelines for clean working conditions. Refer to
⇒ 3.1 Parking/Auxiliary Heater and Fuel System Clean Work‐
ing Conditions, page 4 .
– Move the front seats all the way forward.
– Switch off the ignition.
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
1. Fuel Tank 11
ProCarManuals.com

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Golf Sportsvan:
– Remove the right rear seat. Refer to ⇒ Body Interior; Rep. Gr.
72 ; Rear Seats; Bench Seat / Single Seat, Removing and In‐
stalling .
– Partially loosen the cover -1- in the carpet at the separating
line -arrow-.
– Do not separate the cover completely from the carpet so that
later it will be installed correctly.
– Only loosen so far that the cover can be folded up.
– Fold up the cover in the direction of the -arrow-.
Golf and Golf Wagon:
– Remove the rear bench seat. Refer to ⇒ Body Interior; Rep.
Gr. 72 ; Rear Seats; Bench Seat / Single Seats, Removing
and Installing .
Continuation for All Vehicles:
– Drain the fuel tank. Refer to
⇒ 1.3 Fuel Tank, Draining, page 35 .
– Unclip the sealing flange cover -1- at the tabs -arrows- using
the -3409- .
– Unclip the grommet -1- downward out of the cover -2-.
– Guide the cover -2- on the wiring harness -3- toward the rear.
– Unlock and disconnect the connector -1- from the sealing
flange.
– If equipped, disengage the connector -2- for the parking heater
Metering Pump - V54- on the sealing flange and move it to the
side.
– Disconnect the connector -2-.
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
12 Rep. Gr.20 - Fuel Supply
ProCarManuals.com

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– Lift the tab -2- in the direction of the -arrow A- by using a finger
to reach between the floor panel and the fuel tank.
– At the same time, carefully pull the Fuel Pump Control Module
- J538- -1- out of the mount at the wiring harness -3- in the
direction of the -arrow B-.
– Remove the Fuel Pump Control Module - J538- toward the
inside between the fuel tank and the floor panel.
– Open the fuel filler door unit -2-.
– Clean the area around the fuel filler neck.
– Remove the cap -1- for the fuel filler neck.
Note
Seal the fuel filler neck opening with a clean plug to prevent any
dirt from getting in.
– Remove the fuel filler door unit -2-. Refer to ⇒ Body Exterior;
Rep. Gr. 55 ; Fuel Filler Door Unit; Fuel Filler Door Unit, Re‐
moving and Installing .
– Remove the right rear wheel. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 44 ; Wheels, Tires; Changing a Wheel .
– Remove the right rear wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Overview - Rear
Wheel Housing Liner .
– Remove the rear underbody trim panel. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 66 ; Underbody Trim Panel; Underbody Trim
Panels, Removing and Installing .
– Remove the fuel filler neck bolts -1 and 2-.
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
1. Fuel Tank 13
ProCarManuals.com

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– Disconnect the vent lines -1 and 2- from the EVAP canister.
Disconnect the connector couplings. Refer to
⇒ 4.1 Connector Couplings, Disconnecting, page 62 .
– Unclip the breather line from bracket -arrows-.
– Unclip the breather lines -1 and 2- at the bracket -arrows-.
– Remove the exhaust system rear section. Refer to ⇒ Rep. Gr.
26 ; Exhaust Pipes/Mufflers; Muffler, Removing and Installing .
– Remove the fuel line -1- from the underbody. Disconnect the
connector couplings. Refer to
⇒ 4.1 Connector Couplings, Disconnecting, page 62 .
WARNING
The fuel line is under pressure.
Fuel poses a risk of injury to the eyes and skin.
Wear protective eyewear and protective clothing to avoid injury
and contact with skin. Place a cleaning cloth around the con‐
nection point before loosening hose connections. Carefully
open the connection point to release the pressure.
– Disconnect the breather line -2-. Disconnect the connector
couplings. Refer to
⇒ 4.1 Connector Couplings, Disconnecting, page 62 .
Vehicles with Parking Heater:
– Remove the fuel line -1- from the parking heater. Disconnect
the connector couplings. Refer to
⇒ 4.1 Connector Couplings, Disconnecting, page 62 .
– If equipped, remove the rear underbody trim panel. Refer to
⇒ Body Exterior; Rep. Gr. 66 ; Underbody Trim Panel; Un‐
derbody Trim Panels, Removing and Installing .
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
14 Rep. Gr.20 - Fuel Supply
ProCarManuals.com

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– Press the lever -2- on the brake caliper in the direction of the
-arrow- and disengage the brake cable -1-.
– Press the tabs -3- together and remove the brake cable from
the bracket -4- on the brake caliper.
– Unclip the parking brake cable -4- from the bracket
-arrow A-.
– Pull the parking brake cable out of the guide -arrow B- on the
bracket -3-.
– Remove the bolts -2- and pivot the trailing arm -1- downward.
– Remove the bolt -4-.
– Remove the bracket for the exhaust system.
– Remove the bolt -2- and remove the mounting strap.
– Place the -VAS6931- under the fuel tank for support.
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
1. Fuel Tank 15
ProCarManuals.com

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– Remove the bolts -1 and 3-.
Note
♦
To improve clarity, the fuel tank is shown without the -
VAS6931- .
♦ A second technician is required to remove the fuel tank.
– Lower the fuel tank using the -VAS6931- .
– By turning it accordingly, lower the fuel tank sideways.
– Pay attention to the lines to the EVAP canister, unclipping
them if necessary.
– Guide the filler neck out between the rear axle and the body.
Installing
Install in reverse order of removal. Note the following:
– Guide the filler neck between the rear axle and the body.
Note
Disconnect the connector couplings. Refer to
⇒ 4.1 Connector Couplings, Disconnecting, page 62 .
– If equipped, make sure the Metering Pump - V54- is seated
securely on the bracket.
– Make sure to guide the fuel filler neck correctly into the opening
in the body.
– Make sure the vent and fuel lines are routed without kinks.
– Make sure the supply, return and breather lines are still clipped
to the fuel tank after the fuel tank has been installed.
– Position the fuel tank together with the mounting strap on the
underbody using the -VAS6931- .
– Note the correct installation location for the exhaust system
bracket. Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Muffler;
Overview - Muffler .
– Note the location of the mounting strap.
– Make sure the line connections are secure.
– Check the fit by pulling on it.
Golf 2015 ➤ , Golf Variant 2015 ➤
Fuel Supply - Gasoline Engines - Edition 01.2016
16 Rep. Gr.20 - Fuel Supply
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